EP3830012B1 - Creel loading apparatus and system - Google Patents
Creel loading apparatus and system Download PDFInfo
- Publication number
- EP3830012B1 EP3830012B1 EP19844266.7A EP19844266A EP3830012B1 EP 3830012 B1 EP3830012 B1 EP 3830012B1 EP 19844266 A EP19844266 A EP 19844266A EP 3830012 B1 EP3830012 B1 EP 3830012B1
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- European Patent Office
- Prior art keywords
- yarn
- creel
- platform
- gripper
- axis
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H67/00—Replacing or removing cores, receptacles, or completed packages at paying-out, winding, or depositing stations
- B65H67/06—Supplying cores, receptacles, or packages to, or transporting from, winding or depositing stations
- B65H67/064—Supplying or transporting cross-wound packages, also combined with transporting the empty core
- B65H67/065—Manipulators with gripping or holding means for transferring the packages from one station to another, e.g. from a conveyor to a creel trolley
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H49/00—Unwinding or paying-out filamentary material; Supporting, storing or transporting packages from which filamentary material is to be withdrawn or paid-out
- B65H49/02—Methods or apparatus in which packages do not rotate
- B65H49/04—Package-supporting devices
- B65H49/14—Package-supporting devices for several operative packages
- B65H49/16—Stands or frameworks
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H67/00—Replacing or removing cores, receptacles, or completed packages at paying-out, winding, or depositing stations
- B65H67/02—Arrangements for removing spent cores or receptacles and replacing by supply packages at paying-out stations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H67/00—Replacing or removing cores, receptacles, or completed packages at paying-out, winding, or depositing stations
- B65H67/06—Supplying cores, receptacles, or packages to, or transporting from, winding or depositing stations
- B65H67/063—Marking or identifying devices for packages
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H67/00—Replacing or removing cores, receptacles, or completed packages at paying-out, winding, or depositing stations
- B65H67/06—Supplying cores, receptacles, or packages to, or transporting from, winding or depositing stations
- B65H67/067—Removing full or empty bobbins from a container or a stack
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02H—WARPING, BEAMING OR LEASING
- D02H1/00—Creels, i.e. apparatus for supplying a multiplicity of individual threads
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2701/00—Handled material; Storage means
- B65H2701/30—Handled filamentary material
- B65H2701/31—Textiles threads or artificial strands of filaments
Definitions
- This invention relates to a creel loading apparatus and a system comprising such a creel loading apparatus.
- the present invention provides a creel loading apparatus according to claim 1.
- the creel loading apparatus comprises a frame and a platform that is movable along the frame on a first axis and a second axis that is perpendicular to the first axis.
- a rotary actuator is configured to rotate at least a portion of the platform about the first axis.
- a gripper is movably attached to the at least a portion of the platform that is configured to rotate about the first axis.
- the gripper is configured to releasably engage an inner surface of a yarn package.
- a linear actuator is configured to move the gripper along a linear actuator axis that is perpendicular to the first axis, wherein the linear actuator comprises a first stage and a second stage, wherein the first stage comprises a servo motor that is configured to move the gripper along the linear actuator axis, and wherein the second stage comprises a pneumatic actuator that is configured to move the gripper along the linear actuator axis.
- At least one camera can be attached to the platform.
- the at least one camera can be configured to detect a diameter of a measured yarn package corresponding to a remaining quantity of material on the measured yarn package.
- At least one processor can be is configured to receive an image of the measured yarn package from the at least one camera, and approximate the remaining quantity of material on the measured yarn package based on the image of the measured yarn package.
- the present invention further provides a system according to claim 6 that comprises the creel loading apparatus, a staging area, and a robotic arm comprising a robotic arm gripper at a distal end of the robotic arm.
- the robotic arm and creel loading apparatus are positioned with respect to the staging area so that the robotic arm can deliver yarn packages to the staging area, and the gripper of the creel loading apparatus can receive the yarn packages from the staging area.
- the system can further comprise a creel, wherein the creel comprises the staging area.
- Ranges can be expressed herein as from “about” one particular value, and/or to "about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
- the terms "optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.
- a creel assembly 500 having an outer wall 502, a plurality of yarn package engagement locations 504, a multi-axis robot 506, and at least one processor.
- the outer wall can define an interior space 508, and the plurality of yarn package engagement locations 504 can be distributed within the interior space. It is contemplated that the outer wall of each creel assembly 500 can be provided in any desired shape, including, without limitation, a circular, square, octagonal, or pentagonal shape.
- the multi-axis robot can be fixedly secured within the interior space and positioned to selectively engage yarn packages within the interior space.
- the multi-axis robot 506 can be provided on a pedestal.
- the multi-axis robot can be configured to selectively access the plurality of yarn package engagement locations.
- the at least one processor can be communicatively coupled to the multi-axis robot and configured to receive an input corresponding to a selected action by the multi-axis robot. Methods of using the creel assembly are also disclosed.
- modular creel systems comprising a plurality of the disclosed creel assemblies, with each creel assembly serving as a respective creel module.
- the modular creel systems can comprise an automated feeder assembly configured to selectively deliver yarn packages to the plurality of creel assemblies.
- the plurality of creel assemblies can comprise at least two vertically stacked creel assemblies. Additionally, or alternatively, the plurality of creel assemblies can comprise at least two horizontally adjacent creel assemblies. Methods of using and assembling the modular creel systems are also disclosed.
- the modular creel system can comprise a plurality of creel assemblies that can be positioned in a first configuration during a first creeling (tufting or warping) operation and that can be positioned in a second configuration during a second creeling (tufting or warping) operation, with the first and second configurations being different from one another.
- additional creel assemblies can be coupled to an initial group of creel assemblies in an additive fashion to expand a given creel system.
- the configuration of the creel will be standard, flexible, and modular to provide creel warping and tufting cells.
- each creel assembly can function as a creel module.
- the disclosed creel assemblies can fit within a floor space of 42 feet (12.8016 m) wide by 49 feet (14.9352 m) long with a max ceiling height of 20 feet (6.096 m).
- the creel's footprint can be expanded or shrunk, depending on the need. Accordingly, creels having smaller footprints can be provided.
- the multi-axis robot of each creel assembly can be a centrally-located servicing robot.
- the feeder assembly can comprise a robotic feeder assembly.
- the multi-axis robot of each creel assembly can have a robotic arm mounted to the floor (e.g., using a base) or the ceiling (e.g., using a gantry) of the creel assembly.
- the robotic arm can be configured to use 360 degree access to reach all yarn positions within the yarn assembly.
- the creel system can be a multi-level system that can be added or subtracted onto to achieve a desired creel configuration for warping or tufting operations. It is contemplated that the number of stacked creel assemblies can be two or three, with most operations being conducted with a two-level stacked configuration.
- upper levels of the disclosed creel systems can comprise catwalk linkages to adjacent creel assemblies.
- catwalk linkages can allow operators to access multiple creel assemblies at the same level without having to climb up and down, thereby maximizing human labor efficiency and productivity.
- upper levels of the disclosed creel systems can comprise a bolt on catwalk 520 surrounding the operating area and a mechanism (e.g., a ladder) for accessing the upper level from a lower level within the creel system.
- a mechanism e.g., a ladder
- a creel section i.e., a vertical column of yarn package engagement locations
- a creel section can be no more than 6 or 8 (even numbers) yarn cones high. It is contemplated that the use of a limited, even number of yarn cones in this fashion can allow for use of a dual or quad end effector (coupled to the robot arm) to make the loading/unloading process more efficient.
- creel assemblies as disclosed herein are not limited to cone-style packages, for the purposes of the disclosure it should be understood that the terms yarn cone and yarn package are used interchangeably herein.
- the plant operator can selectively adjust the yarn package engagement locations and positions of creel assemblies to achieve a designated creel configuration, for example, by engaging a manual mode.
- each creel level within a creel system can service at least 1,844 cone positions (a two-level can service at least 3,688 cone positions). However, it is contemplated that each creel level can be configured to service more or fewer cone positions depending upon the creel assembly configuration and space constraints.
- the bases of the disclosed multi-axis robots are stationary.
- the disclosed creel assemblies and creel systems do not include or make use of vision systems.
- the creel operator 512 can have zoned access 510 from the perimeter of each yarn assembly to permit performance of tying and splicing tasks. It is contemplated that all non-maintenance access to the creel can be provided from outside the wall of the creel assembly. While one zone can have human interaction (an interface mode), other zones (optionally, all other zones within the creel assembly) can be in a running or operational order or mode. Within each creel level, the number of zones configured for human interaction can be selectively adjusted. Optionally, within each creel level, it is contemplated that the number of zones configured for human interaction can range from four to eight.
- the disclosed robotic components can be manufactured by ABB or Yaskawa (Motoman).
- the disclosed creel assemblies and creel systems can comprise processing units, including programmable logic controllers (PLCs), to permit communication among the various system components.
- PLCs programmable logic controllers
- such PLCs can be AB L83 PLCs manufactured by Allen Bradley.
- the disclosed creel assemblies and creel systems can comprise one or more drive systems for effecting movement of yarn packages.
- drive systems can be manufactured by Yaskawa.
- the disclosed creel assemblies and creel systems can comprise at least one human-machine interface (HMI) for receiving inputs from a creel operator.
- HMIs can be provided as a Siemens 22" Comfort Panel; however, it is also contemplated that portable HMIs such as tablets and other remote computing devices (e.g., smartphones) can be used.
- each creel assembly can have a maintenance access door 514 to permit access to the stationary robot within the creel assembly.
- the maintenance access door can have an emergency stop protocol (e.g., an emergency stop switch that is triggered) if opened during operations. For example, all moving parts can be halted.
- the maintenance access door can be formed as a portion of the outer wall of the creel assembly such that the inner surface of the access door can be used as creel space.
- all yarn exit points can be oriented upwardly, with the yarn curving over the top of the outer wall of the creel assembly to bridge the distance between the creel assembly and the tufting and/or warping machine(s).
- each creel level can have at least one status light (e.g., at least one Andon light) that is communicatively coupled to a processor and configured to provide an indication of a status of system automation.
- the status light(s) can vary between on and off, vary between solid and flashing, vary in flashing frequency, and/or change color depending on the status.
- cones of yarn i.e., yarn packages
- machine vision can be used to effectively find cones of yarn on a pallet and place them on an inbound system such as a conveyor.
- a plastic cap as known in the art, can be installed on the yarn cone.
- cones of yarn fed into the creel can be provided with indicia that can be scanned to verify lots of yarn and consumption amounts/rates. It is contemplated that this can be done within the creel or outside of the creel via auxiliary automation.
- the robot within each creel assembly can comprise an end effector that loads multiple cones at a time.
- the end effector can be a dual, tri, or quad end effector. It is contemplated that the creel assembly can have a singular end effector to manipulate around the yarn in process.
- the robot can place plastic caps onto the ends of the yarn package.
- a programming interface can be provided to receive one or more inputs corresponding to a proper creel configuration.
- locations of the cones and creel population configurations can be stored in memory and associated with particular processes and operations.
- an electro mechanical dumbwaiter can be bolted or otherwise secured onto the exterior of the creel.
- the dumbwaiter can comprise a platform that selectively moves vertically along the creel. It is contemplated that the dumbwaiter can be configured to deliver a selected number of yarn packages (e.g., four yarn packages) at a time.
- the creel system can comprise a light (e.g., an Andon light) that provides a visual indication when the dumbwaiter is in service and safety protocol to prevent human injury.
- a light e.g., an Andon light
- other visual indicators and safety protocols can be used.
- a separate scanner or camera can be provided with the end effector and configured to produce an alert or signal indicative of a yarn cone position that is empty and/or in need of prompt attention.
- the alert or signal can be received by the processing units within the automated yarn system as disclosed herein. It is further contemplated that the alert or signal can be received by a creel operator (optionally, through a remote computing device accessed by the operator).
- the robot of each yarn assembly can be configured to continually scan for empty cone positions.
- the robot can be configured to replace an empty yarn cone without prompting from a creel operator.
- the operator can be responsible to make a decision and to provide at least one input directing the replacement of a cone of yarn or a swap between yarn cone positions.
- the robot can be configured to remove the cones and place them in a location to be removed from the cell via conveyance or a gravity chute, or placed into a container by a service robot.
- the yarn system can comprise collision prevention systems provided on the robotic arms to detect if a human mistake is made and the robot tries to load a position that is already loaded. Additionally, in these aspects, if the robot goes to pick up a cone of yarn and there is not one there, the robot can be configured to scan for a minimum cone diameter in order to evaluate and confirm whether there is no yarn present. In both of these conditions, the robot can be configured to enter a fault condition and provide feedback on the HMI to prompt manual intervention by a creel operator.
- a human interface can be provided as a remote computing device (e.g., tablet, portable electronic pad, smartphone, or the like) or other conventional HMI device.
- the human interface can allow a creel operator to make manual changes of yarn positions for optimization of the creel and to minimize waste of yarn.
- Logic within the creel can maintain track of cone locations and alert the creel operator if they assign a populated location mistakenly.
- creel operators can manually tie or splice ends of yarn together. It is contemplated that these creel operators can be provided with zoned access from the perimeter of the wall of each creel assembly. While a creel operator is within a particular zone, the robotic arm can continue to service the other zones of the creel assembly (module) (i.e., except for where the zoned section is interrupted for manual work, operations within the creel assembly will continue).
- the HMI interface can display live positions of yarn within the creel.
- the monitoring of live positions of yarn can be done with logic and not sensors.
- sensors can be used as well.
- each creel assembly can have a display monitor (optionally, a 55" monitor) to show the live view and live status of all creel locations with picture-in-picture (PIP) of one or two cameras within the creel assemblies to permit monitoring of activity inside the operating area.
- PIP picture-in-picture
- each creel can have remote viewing, monitoring, and diagnostic capability.
- each creel location can be configured to accommodate a cone of yarn up to 15" (38.1 cm) in diameter.
- each cone can have a 2.75" (6.985 cm) inside diameter and a 3-1/8" (7.9375 cm) outside diameter.
- each yarn cone can be 11-7/16" (29.05125 cm) in length.
- the automation disclosed herein can be configured to handle up to a 25 lb (11.3398 kg) cone of yarn at each yarn cone position.
- a dual end effector can have a 50 lb (22.6796 kg) capacity. If a tri end effector is used, it is contemplated that the end effector can have a 75 lb (34.0194 kg) capacity. If a quad end effector is used, it is contemplated that the end effector can have a 100 lb (45.3592 kg) capacity.
- the creel it is possible for the creel to have a plurality (e.g., 4-6) of different types of yarns loaded into the creel at the same time.
- the programming logic of the creel can allow a creel operator to load the creel in any configuration within the total number of yard positions.
- each cone of yarn can be verified via scanning an associated barcode (or other indicia) prior to entering the creel.
- the HMI can keep track of the yarn ID on the display (screen) for the operator to know what yarn type is running in a particular location within the creel.
- the HMI can provide the ability to do yarn optimization in either a manual fashion or using automated processor control.
- the HMI can be configured to permit movement of yarn cones from one position to another position in a manual fashion to provide optimization near the end of a tufting run.
- An exemplary loading process can begin with a lift driver or AGV delivering a pallet of yarn to a fixed inbound/outbound position 530.
- the dunnage can be stripped and discarded by manual labor.
- the HMI can be set to operate in an "Auto" mode and used to load the creel.
- a material handling robot 532 can locate each package of yarn and load the yarn package into the proper position for transport into the creel. If the robot discovers nonconforming packages, the system can produce an alarm and alert the creel operator to remove the package of yarn.
- the material handling robot can place plastic caps onto the packages before entry into the creel.
- the material handling robot can generate an alarm and call for an additional pallet of yarn; alternatively, an additional pallet can be automatically indexed into position for engagement with the material handling robot.
- yarn delivery can be staged on a conventional conveyor 534 or a just-in-time (JIT) delivery conveyor. Once the pallet is empty, the pallet can be transported to an outbound position for takeaway. The loaded yarn can then be transported into the creel using the conveyor assembly.
- the walls of the creel assemblies can be provided with one or more openings for receiving portions of the conveyor assembly and permitting delivery of yarn packages to a location that is accessible from the robots within the interior spaces of the creel assemblies. Human creel operators can make all yarn connections to ensure that each yarn cone is connected to the tufter.
- the automation can be configured to load a package of yarn (received from the conveyor assembly) onto a selected position within creel assembly in the same general manner in which yarn packages are loaded by the material handling robot.
- the robot within each creel assembly when in "Auto” mode, can be configured to use a scanning end effector to look for empty cones of yard and deposit them into an ejection shoot.
- the HMI and Andon lights can prompt the operator to give instruction to move a cone of yarn from one position to another or to load a new cone automatically. It is contemplated that this process can be employed to optimize yarn usage. In exemplary aspects, it is contemplated that human creel operators can connect or disconnect all yarn connections to ensure that no cones are pulled out of the tufter.
- human creel operators disconnect all yarn connections to ensure that no cones are pulled out of the tufter.
- the HMI can be placed in "Strip" mode to strip the creel. In this mode, yarn is transported out of the creel, and all leftover cones of yarn can be transported by the material handling robot to the outbound position.
- a lift driver or AGV can remove the full pallet and replace the full pallet with an empty pallet for loading additional yarn cones.
- the system can be configured to alert the HMI that the creel is empty and turn on a light (e.g., an Andon light) or other visual indicator to ready itself for loading.
- a light e.g., an Andon light
- a textile manufacturing system 2 can comprise a creel 4 and a warper 6 or other yarn processing apparatus such as a tufter or a heat set tunnel.
- the creel 4 can comprise a plurality of creel modules 10.
- Each creel module 10 can comprise an outer wall 12 and a plurality of yarn package engagement locations 14.
- the yarn package engagement locations 14 can be bullhorns 16 that comprise a generally cylindrical portion 18 and a spreader 20 that biases outwardly against an interior of a yarn package in order to retain the package on the yarn package engagement location.
- Pull-off guides 22 e.g., half-cylindrical pull-off guides
- a creel can cooperate to form a creel 4 that feeds a yarn processing apparatus.
- a creel can comprise a plurality of modules (e.g., between one and twenty modules).
- each creel module 10 can comprise a first side 30 and an opposing second side 32, wherein the first side 30 and second side 32 are spaced by a passage 34 through which a gantry travels as further disclosed herein.
- Each side can comprise a plurality of sections 36 (e.g. between two and twenty sections).
- Each section can comprise a plurality of horizontal rows (e.g., between six and twenty rows) and a plurality of vertical columns (e.g., four columns) of yarn package engagement locations 14.
- each section can be positioned between respective horizontal separators of the frame of the creel as shown in Figures 7a-7b .
- Each module can comprise one or a plurality of levels 38.
- a catwalk 40 at each level 38 can provide operators with access to the creel.
- a warper system 2a can comprise a single creel module 10.
- the single creel module 10 can be two levels high, with eight sections per side.
- the single creel module 10 can hold 640 packages, or 320 ends, that are connected to a warper 6.
- a tufting system 2b can comprise a pair of creel modules 10.
- the pair of creel modules 10 can be two levels high and have ten sections per side.
- the pair of creel modules 10 can, in combination, hold 1844 packages, or 922 ends, that are connected to a tufting machine.
- a tufting system 2c can comprise three modules 10.
- the tufting system can be two levels high with five sections per side.
- the three creel modules 10 can, in combination, hold 1844 packages, or 922 ends, that are connected to a tufting machine.
- a tufting system 2d can comprise four modules 10.
- the tufting system can be two levels high, with ten sections per side.
- the tufting system can hold 3688 packages, or 1844 ends, that are connected to a tufting machine.
- a yarn creel system can comprise a single module one level high with eight sections per side that can hold 640 packages, or 320 ends, that are connected to a heat set tunnel.
- a plurality of creel modules 10 can be coupled to form an enlarged creel, for example, to perform a tufting operation. At least one of the plurality of creel modules can be decoupled from the other creel modules of the plurality of creel modules after the tufting operation to form a smaller creel (with fewer creel modules). Due to the modularity of the creel system, further creel module combinations can be provided as desired.
- a creel loading apparatus, or gantry 100 comprises a frame 102.
- the frame 102 can comprise a horizontal track 102a and a mast 102b that is movable via a motor (e.g., a servo motor) on the horizontal track 102a along a first axis 106.
- the frame 102 can include integrated conduits 103 for providing power, air, and a vacuum source.
- a platform 104 can comprise a first portion 104a that moves vertically, via a motor (e.g., a servo motor), along the mast 102b.
- the platform 104 is movable along the frame relative to the first axis 106 and a second (vertical) axis 108.
- the platform can further comprise a second portion 104b that is rotatable with respect to the first portion 104a about a rotary axis 109 that is parallel to the first axis 106.
- a rotary actuator 112 can be configured to rotate the second portion 104b of the platform 104 about the rotary axis 109.
- a gantry control panel 107 can attach to the mast 102b.
- a first linear actuator 112 can be attached to the second portion 104b of the platform 104.
- the first linear actuator 112 can be extendable along a linear actuator axis 114.
- a gripper 116 can attach to an end of the first linear actuator 112.
- the gripper 116 can be provided as a component of end of arm tooling (EOAT).
- the gripper 116 can comprise a plurality of jaws 118 that extend radially from each other in order to grip an inner surface 122 ( Figure 6 ) of a yarn package 120.
- the plurality of jaws 118 can optionally have cylindrical surfaces.
- the gripper 116 can optionally define a cylindrical surface.
- the linear actuator comprises a first stage 130 and a second stage 132.
- the first stage 130 can comprise a sub platform 134 that is movable on a track 136 along the linear actuator axis 114.
- a servo motor 138 can drive a belt 140 to move the sub platform 132 along the track 136.
- the second stage 132 can comprise a pneumatic actuator 142 that is attached to the sub-platform 132 so that movement of the first stage 130 translates the pneumatic actuator 142 along the linear actuator axis 114.
- the pneumatic actuator 142 can comprise a pneumatic cylinder 144 having a piston rod 146 therein.
- the gripper 116 can attach to a distal end of the piston rod 146.
- a service robot can stage yarn packages in a staging area within the creel, and the gantry can then transport the yarn packages from the staging area to desired yarn package engagement locations on the creel.
- the staging area can be set closer to a central plane that includes the first axis 106 and the second axis 108.
- the first stage 130 can position the grippers in a first transverse position, relative to a transverse horizontal axis that is perpendicular to the first axis 106, from which the grippers can selectively access, via extension of the second stage 132, yarn packages in the staging area.
- the first stage 130 can then position the grippers in a second transverse position relative to the transverse horizontal axis from which the grippers can selectively position, via extension of the second stage 132, yarn packages on yarn package engagement locations on the creel.
- the dual stage actuator can enable the gantry to be configured for use in various creel module widths (i.e., the horizontal dimension perpendicular to the creel module's longitudinal dimension).
- the first stage 130 can be set at a fixed position during normal operation, and the second stage 132 can be used for placing the yarn packages. Additionally, the first stage's position can be adjusted to improve positioning of the yarn packages with respect to the yarn package engagement locations when the second stage 132 is fully extended.
- a second linear actuator 150 and a third linear actuator 152 can attach to the second portion 104b of the platform 104, wherein each of the second linear actuator and the third linear actuator has the same construction and configuration as the first linear actuator 112.
- Each of the second linear actuator 150 and the third linear actuator 152 can have a gripper 116 attached at a distal end.
- the gantry 100 can manipulate three yarn packages 120 at a time.
- Each of the first linear actuator 112, the second linear actuator 150, and the third linear actuator 152 can be independently actuatable.
- the first linear actuator 112, the second linear actuator 150, and the third linear actuator 152 can be movable in concert (i.e., simultaneously or sequentially).
- the gantry can comprise two, four, five, or more linear actuators and respective grippers can independently manipulate a corresponding number of yarn packages.
- the linear actuators and respective grippers can collectively be referred to as end effectors 158.
- a first camera 160 can attach to the second portion 104b of the platform 104.
- the first camera 160 can be configured to detect a diameter of a yarn package 120.
- the first camera 160, and each of the cameras described herein, can optionally be an IFM O3D302.
- a computing device 1001 ( Figure 19 ) in communication with the camera 160 can be configured to approximate a remaining quantity of material on the yarn package 120.
- the first camera 162 can be at a fixed position from each yarn package on the respective yarn package engagement location.
- the remaining quantity of yarn can be approximated based on the amount of area that the yarn package encompasses within the camera's field of view.
- the measurement error can be within plus or minus five percent.
- the first camera can be disposed so that it captures images of yarn packages 120 on a first side (with respect to a plane that includes the first axis 106 and the second axis 108) of the gantry, and a second camera 162 (labeled but not shown) can be disposed opposite the first camera so that it can capture images of yarn packages 120 on the opposite side of the gantry.
- a staging platform 170 can be movable along the frame 102.
- the staging platform 170 can attach to the mast 102b so that the staging platform 170 moves along the first axis 106 with the platform 104.
- the staging platform can comprise a plurality of bullhorns 172 that are configured to receive yarn packages 120 thereon.
- the bullhorns 172 can be positioned so that when the second portion 104b of the platform 104 is rotated so that the linear actuators axes are vertical, the bullhorns are axially aligned with the respective linear actuators' axes 114.
- the plurality of grippers 116 can hold a first plurality of packages 120
- the staging platform can hold a second plurality of packages 120.
- the grippers 116 can position the first plurality of packages 120 on the creel module 10 ( Figure 5 ).
- the rotary actuator 112 can then rotate the second portion 104b of the platform 104 so that the plurality of grippers 116 are oriented to engage the second plurality of packages 120 on the staging platform 170.
- the plurality of grippers 116 can extend and receive respective packages 120 of the second plurality of packages, retract, and then rotate (optionally, rotating ninety degrees) in order to position the second plurality of packages on the creel module 10.
- the creel module 10 can comprise a staging area 190 at a first end.
- a yarn case staging location 196 can receive one or more yarn cases 198 having a plurality of yarn packages 120 thereon.
- the yarn case staging location 196 can comprise guides 197 ( Figure 15 ) for locating the yarn cases 198.
- the staging area 190 can comprise bullhorns 192 that are similar to bullhorns 16 and are configured to receive yarn packages 120.
- the bullhorns can be vertically spaced along a vertical axis so that when the platform 104 is in a home position 180, the grippers 116 can be positioned to simultaneously receive the yarn packages from the staging area's bullhorns 192.
- each creel module 10 can comprise a pair of opposing staging areas 190 that each comprise two rows of three vertically spaced bullhorns 192.
- a service robot 200 can be disposed with respect to the staging area 190 and the yarn case staging location 196 so that the service robot can receive yarn packages from the yarn cases in the yarn case staging location 196 and load yarn packages 120 onto the bullhorns 192 of the staging area 190.
- the service robot 200 can comprise a base 202 that is anchored to the floor.
- An arm 204 can have a first end 206 that attaches to the base 202 and an operational end 208 opposite the first end 206.
- the arm 204 can have at least four degrees of freedom.
- the service robot 200 can have six axes of movement.
- the service robot 200 can comprise a plurality of actuators that are configured to actuate movement between respective arm components at each arm joint.
- a gripper assembly 210 can attach to the operational end 208 of the arm 204.
- the gripper assembly 210 can comprise a plurality of grippers 116 (e.g., three grippers) that are spaced so that they can simultaneously load the bullhorns 192 of the staging area (i.e., having the same spacing as that of the grippers 116 on the gantry).
- the gripper assembly 210 can comprise a central gripper 116a that is in a fixed position with respect to the gripper assembly 210.
- the gripper assembly 210 can further comprise a first gripper 116b on a first side of the central gripper 116a and a second gripper 116c on a second side, opposite the first side, of the central gripper 116a.
- the first and second grippers 116b, 146c can be coupled (e.g., attached) to respective linear actuators 212 that position the respective first or second actuator closer to and away from the central gripper 116a to accommodate variations in spacing of yarn packages.
- the linear actuators 212 can be in communication with a processor of a computing device as disclosed herein that controls their actuation.
- the linear actuators 212 can have about two inches (5.08 cm) of travel.
- yarn packages can be spaced 10.5 inches (26.67 cm) from center to center when on a case, bullhorns in the staging area can be spaced 12.5 inches (31.75 cm) apart from center to center.
- the linear actuators 212 can provide the travel to adapt for the spacing difference.
- the service robot 200 can further comprise a camera 220.
- the camera 220 can be a three-dimensional camera.
- the camera 220 can be in communication with a computing device 1001 ( Figure 26 ).
- the computing device 1001 can receive images of a given yarn case 198 in the yarn case staging location 196 from the camera 220 and process the images to determine a quantity of yarn packages 120 on said case.
- the camera can be a range camera. That is, the camera (and a coupled processor) can determine a distance between the camera and an object (e.g., a yarn package 120).
- the camera and coupled processor can be configured to determine presence or absence of yarn packages in a horizontal array.
- a yarn case can comprise a plurality of stacked horizontal layers.
- the camera can capture the top layer for determining the presence or absence of yarn packages on the top layer.
- the system can detect the missing package 250 (i.e. an empty location without a package present).
- the camera and coupled processor can further be configured to determine a height of yarn packages, corresponding to a number of stacked layers of yarn packages.
- the gripper assembly 210 can comprise a dunnage removal assembly 230.
- the dunnage removal assembly can comprise one or more suction cups 232.
- Each suction cup 232 can be in fluid communication with a vacuum source 234 (e.g., a hose can extend between a vacuum pump and the suction cup 232.
- the suction cups 232 can be configured to grip dunnage 186 ( Figure 18 ), and the service robot 200 ( Figure 18 ) can then move the gripper assembly 210 to lift the dunnage from the case 198.
- the service robot 200 can then move the dunnage to a dunnage area 188 (assuming the dunnage area 188 has capacity to receive the dunnage; if the dunnage area is full, the system can notify the operator via, for example, a message or an indicator, that the dunnage area must be emptied).
- the service robot 200 can repeat the dunnage removal process for a plurality of layers of dunnage.
- the yarn case 198 can be received in a designated position (e.g., a yarn case staging location 196).
- the yarn packages 120 on a given yarn case 198 can be in fixed positions on the yarn case. In this way, the service robot 200 can, in knowing the position of the yarn case 198, determine the positons of each yarn package 120.
- the textile manufacturing system 2 can be controlled by a .net application on a computing device 1001 ( Figure 26 ). Operators can interface with the .net application via an input/output interface 1010 ( Figure 26 ). In some embodiments, the interface can enable the operator to control operation of the creel system. For example, the operator can input a stock keeping unit (SKU) corresponding to a final flooring (e.g., carpet) product (referred to as a "finished product SKU”), thereby causing the computing device 1001 to load the mapping database for the finished product SKU.
- SKU stock keeping unit
- the interface can provide the operator with information about the process, such as whether or not certain packages need to be loaded onto the creel, in which yarn case staging locations yarn cases comprising such packages need to be positioned so that the textile manufacturing system 2 can load the yarn cases, or whether certain packages need to be spliced.
- Each finished flooring product can have a corresponding SKU.
- Each finished product SKU can have a corresponding creel map that can be programmed and uploaded into the computing system 1001.
- the computing device 1001 can perform a method 400 for assigning and monitoring staging of yarn packages. From a starting block 405, method 400 can proceed to stage 410, where the computing device 1001 receives a finished flooring product identifier. For example, an operator can input a specific finished flooring product identifier (e.g., a finished product SKU) into the computing device 1001. From stage 410, the method 400 can proceed to stage 415, where the computing device 1001 receives a creel map.
- a finished flooring product identifier e.g., a finished product SKU
- the computing device 1001 can receive (e.g., download from a database, as further disclosed herein), based on the input finished product identifier, a creel map comprising a plurality of yarn engagement locations and respective identifiers corresponding to yarn packages to be received at each yarn package engagement location.
- the map can store each yarn package engagement location and link each yarn package location to a corresponding yarn package SKU.
- the map can be displayed (e.g., on the display of a computing device) as a spreadsheet comprising a first column that lists each yarn engagement location, and a second column that lists the yarn package identifier for the corresponding yarn engagement location.
- the respective identifiers can be, for example, SKUs of each yarn package.
- the map can be displayed as a visualization of the creel.
- the map can be displayed as a three-dimensional rendering of the creel having different colors, text, and/or graphics corresponding to different yarn package SKUs.
- the method 400 can proceed to stage 420, where the computing device 1001 can assign yarn case staging locations. That is, the computing device can, using the creel map, assign yarn case staging locations for receiving respective yarn cases.
- Each yarn case can comprise a pallet having a plurality of yarn packages that each have the same identifier (e.g., SKU).
- the computing device can assign a first staging location for receiving a yarn case having yarn with the first identifier and a second staging location for receiving a yarn case having yarn with the second identifier.
- the method 400 can proceed to stage 425, where the computing device 1001 determines the yarn cases (if any) that should be positioned at each yarn case staging locations.
- the computing device can provide, on a display, a map of each yarn case staging location and a given yarn case identifier designated to be received at each yarn case staging location.
- the map can include at least one yarn case staging location that is empty.
- method 400 can proceed to stage 435, where the computing device receives an identifier of a yarn case positioned at each yarn case staging location.
- the operator can scan an identifier (e.g., a barcode, QR code, RFID (radio frequency identification) tag, etc.) that corresponds to a yarn case staging location.
- the handheld scanning function can be performed using the computing device 1001, for example, using a camera and an optical scanning application of the computing device. The operator can then scan an identifier (e.g., a barcode, QR code, RFID tag, etc.) on the yarn case.
- the scannable identifier that corresponds to the yarn case staging location can optionally be located at a position at or near the yarn case staging location so that an operator at the yarn case staging location can scan both the yarn case staging location identifier and the identifier on the yarn case that is positioned on the yarn case staging location from the same standing position.
- method 400 can proceed to stage 440, where the yarn case identifier is compared to the yarn case staging location.
- the computing device can determine whether the yarn case is a correct match for the given staging location.
- method 400 can proceed to stage 445, where feedback is provided to the operator if the received yarn case identifier does not match the assigned yarn case identifier. If the yarn case identifier is incorrect, the system can display an error and prevent the service arm 200 from staging the yarn packages until the correct yarn case is positioned in the staging location.
- the system can maintain knowledge of the occupied status (occupied or unoccupied) of each staging location based on scanning yarn cases onto and off of the yarn case staging location. For example, when an operator scans a staging location and then a yarn case, the computing device 1001 ( Figure 26 ) can store in system memory 1012 ( Figure 26 ) that the staging location is occupied. Similarly, as a yarn case (or empty pallet from the yarn case) is removed, the operator can scan the staging location, thereby causing the computing device to store in the system memory 1012 that the staging location is unoccupied.
- RFID or other automated scanning methods can be used to determine when a yarn case is in a staging location. For example, an RFID scanner can be positioned with respect to a staging location so that when a yarn case having a properly-situated RFID tag is placed in the staging location, the RFID scanner can detect the presence of the yarn case.
- the service robot 200 can provide the yarn packages to the gantry 100.
- the gantry can then deliver the yarn to the respective yarn package engagement locations based on the creel map.
- the system memory 1012 ( Figure 26 ) of the computing device 1001 can include a database for monitoring occupancy of yarn packages at each yarn package engagement location. For example, when the gantry places a yarn package on a yarn package engagement location, the computing device can store in the database that the yarn package engagement location is occupied. The computing device 1001 can then check the database before providing instructions to the gantry to place another yarn package. If the computing device 1001 receives instructions to place the yarn package on an occupied yarn package location, the computing device 1001 can provide an error message or otherwise notify an operator that the yarn package location is already occupied. For example, the error message can include text on a display of a computing device, an audible alarm, and/or a status light on a control panel.
- the gantry can purge yarn packages by removing the yarn packages from their respective yarn package engagement locations.
- the gantry and the service arm can further deliver the purged yarn packages to a bin, or to the yarn staging area from which the service arm receives the purged yarn packages and then places the purged yarn packages in the bin.
- the service arm can stack the purged yarn packages into a position based on the package design.
- a pallet can comprise cylindrical or conical studs that are receivable within an inner volume defined by the package's inner surface 122 ( Figure 6 ). Thus, the studs can space the purged yarn packages.
- another pallet can be stacked on top of the full package layer until the case is full, at which point the full case can be removed and replaced with an empty pallet.
- the computing device 1001 can allow for various levels of access.
- the levels can comprise an operator level, a maintenance level, an engineering level, and an administrator level.
- Each level can be permitted or restricted access based on certain rules. For example, in some embodiments, operators can be provided access to load creel maps but not edit creel maps, whereas engineers can be permitted to edit creel maps and override certain parameters.
- a program when executed by a processor of the computing device, can enable an operator to select certain operational modes of the creel system.
- the modes can include a strip creel mode, a load creel mode, a run mode, and a manual creeling mode.
- the program can prompt the operator to verify that the ends of the yarns have been cut and prevent further operation until the operator verifies as such through the user interface as further disclosed herein.
- the program can then prompt the operator to verify that RTI bins (e.g., refuse/package recycle bins) are empty and in proper positions.
- RTI bins e.g., refuse/package recycle bins
- the operator can enter or scan a finished product SKU.
- the program can load the creel map based on the entered finished product SKU and assign yarn case staging locations to receive select yarn cases based on the map.
- the operator can then scan a yarn case or otherwise input an identifier of the yarn case.
- the program can verify that the yarn case corresponds to an assigned yarn case from the map. If the yarn case does not match an assigned yarn case, the program can provide such feedback to the operator (through the user interface such as a text or graphical display). If the yarn case matches the assigned yarn case, the program can then allow the operator to scan a yarn case staging location.
- the program can then determine whether or not the yarn case staging location matches the yarn case.
- the operator can select to move a package from a staging area to a module position.
- the operator can enter or scan a finished product SKU.
- the operator can select the finished product SKU from a drop-down menu, type the SKU into a text input box, or scan a barcode from a book of barcodes corresponding to respective final flooring products.
- the system can position the yarn in the desired yarn package engagement location. If a required yarn package is not present either already on the creel or in a yarn case in a yarn package engagement location, the program can enable the operator to scan at least one yarn package.
- the program can advance to allow the operator to scan a location (e.g., an operator can use a barcode scanner to scan a barcode positioned at a respective yarn package receiving location). If the scanned location matches or is otherwise associated with the yarn package, the program can advance to allow the operator to load the yarn.
- a location e.g., an operator can use a barcode scanner to scan a barcode positioned at a respective yarn package receiving location. If the scanned location matches or is otherwise associated with the yarn package, the program can advance to allow the operator to load the yarn.
- the program can enable the operator to move a yarn package from a yarn package engagement location to a package staging location.
- the program can prompt the operator to verify that the yarn ends are cut.
- the program can verify locations of RTI bin(s). For example, empty RTI bins can be placed in yarn case staging locations.
- an operator can scan the identifier (e.g., barcode) of each yarn case staging location and an identifier (e.g., barcode) on the respective RTI bin, thereby inputting into the computing device the location of each empty RTI bin for receiving yarn packages from the creel. If the RTI bin locations are not verified, the program can prompt the operator to load the RTI bins. Otherwise, the gantry can move the yarn package from the yarn package engagement location to the package staging location.
- the identifier e.g., barcode
- the program can enable the operator to move a yarn package from one yarn package engagement location to another.
- the processor when executing the program, can prompt the operator to verify that the yarn ends are cut. Once affirmed, the processor, when executing the program, can cause the gantry to move the yarn package from a first yarn package engagement location to a second yarn package engagement location.
- the above-disclosed system can be used according to the following process.
- An operator can input the SKU of a finished product. For example, the operator can select the finished product SKU from a drop-down menu, type the SKU into a text input box, or scan a barcode from a book of barcodes corresponding to respective final flooring products. In doing so, the system can load the creel map associated with the loaded SKU of the finished product. Yarn cases can then be staged at yarn case staging locations based on the loaded creel map. An operator can gain access into a fenced off pallet staging area via a hard and/or a soft (e.g., input key code) key. The service robot 200 can be moved to a home position.
- the home position can be a position in which the service robot is spaced from the travel of the gantry to avoid collision and spaced from the yarn case staging locations to allow placement of yarn cases thereon.
- the operator can scan the yarn case's SKU and then the corresponding yarn case staging location.
- the system can prompt the operator to load yarn package caps or verify that yarn package caps are already present on the yarn packages.
- the operator can verify that the yarn case is properly arranged with respect to the yarn case locators.
- the system can prevent the service robot from moving until the pallet sensor(s) is/are detecting yarn cases thereon.
- the service robot in conjunction with the gantry, can then begin loading the respective creel module and continue until the creel is full (with each engagement location being filled in accordance with the creel map).
- the system can pause to allow the operator to scan in and load another yarn case at the yarn case staging location, as described herein.
- the service robot can go into an idle mode (e.g., motionless in the home position) until the gantry opens space in the staging area.
- the service robot can remove the dunnage and place the dunnage in the empty dunnage area, exposing the next layer of yarn packages for engagement with the grippers of the service robot.
- the gantry can begin at a staging wait position (at a position spaced from the staging area).
- the gantry can wait until the service robot positions a sufficient number of yarn packages in the staging area 190.
- the gantry and service robot can maintain knowledge of each other's position in order to avoid collision. For example, the gantry can stay at the staging wait position until the service robot is halted in the home position.
- the gantry can then load the staging platform 170 and then load each of its end effectors 158.
- the gantry can fill the yarn package engagement locations according to the creel map.
- the gantry can enter a check mode.
- the gantry can use its cameras to measure the remaining quantity of yarn on each package.
- the gantry detects a yarn package that is empty or below a threshold (e.g., a minimum operative diameter based on the amount of remaining yarn)
- the gantry can remove the exhausted package spool from the gantry and place it in a discard bin.
- the computing device can determine if a replacement yarn package of the same SKU is available at the creel module's staging area.
- the service robot can place the yarn package in the staging area, and the gantry can place the yarn package in the yarn package engagement location from which the exhausted roll was removed. The system can then notify an operator to splice the yarn. If the yarn package (with the proper SKU) is not available in the staging area 190, the system can cause the service robot to place the yarn package in the yarn case staging location.
- the ends can first be cut (using conventional methods). At least one container must be in place and have capacity to receive yarn packages (or, preferably, be empty). If no bin is in position and with capacity to receive yarn packages, the system can prompt the operator to place or change the container.
- the gantry can remove yarn packages beginning from the far end (opposite the service robot) first.
- the gantry can fill the staging platform 170 (e.g., with three packages) and fill its end effectors.
- the gantry can then place the packages from its end effectors and staging platform in the staging area 190.
- the service robot 200 can pick up the yarn packages from the staging area and place them into the container.
- the creel can be loaded more quickly than conventional system and methods.
- a creel module can be loaded in less than two hours and eight minutes. Because each creel module can be loaded simultaneously, a creel comprising a plurality of modules can likewise be loaded in less than two hours and eight minutes.
- Figure 26 shows a system 1000 including a computing device 1001 for use with the creel system as disclosed herein.
- the computing device 1001 may comprise one or more processors 1003, a system memory 1012, and a bus 1013 that couples various components of the computing device 1001 including the one or more processors 1003 to the system memory 1012. In the case of multiple processors 1003, the computing device 1001 may utilize parallel computing.
- the computing device 1001 can comprise a tablet, a smart phone, a personal computer, a laptop computer, or other suitable device (e.g., handheld computing device).
- the bus 1013 may comprise one or more of several possible types of bus structures, such as a memory bus, memory controller, a peripheral bus, an accelerated graphics port, and a processor or local bus using any of a variety of bus architectures.
- the computing device 1001 may operate on and/or comprise a variety of computer readable media (e.g., non-transitory).
- Computer readable media may be any available media that is accessible by the computing device 1001 and comprises, non-transitory, volatile and/or non-volatile media, removable and non-removable media.
- the system memory 1012 has computer readable media in the form of volatile memory, such as random access memory (RAM), and/or non-volatile memory, such as read only memory (ROM).
- the system memory 1012 may store data such as creel mapping data 1007 and/or program modules such as operating system 1005 and creel mapping software 1006 that are accessible to and/or are operated on by the one or more processors 1003.
- the computing device 1001 may also comprise other removable/non-removable, volatile/non-volatile computer storage media.
- the mass storage device 1004 may provide non-volatile storage of computer code, computer readable instructions, data structures, program modules, and other data for the computing device 1001.
- the mass storage device 1004 may be a hard disk, a removable magnetic disk, a removable optical disk, magnetic cassettes or other magnetic storage devices, flash memory cards, CD-ROM, digital versatile disks (DVD) or other optical storage, random access memories (RAM), read only memories (ROM), electrically erasable programmable read-only memory (EEPROM), and the like.
- Any number of program modules may be stored on the mass storage device 1004.
- An operating system 1005 and creel mapping software 1006 may be stored on the mass storage device 1004.
- One or more of the operating system 1005 and creel mapping software 1006 (or some combination thereof) may comprise program modules and the creel mapping software 1006.
- Creel mapping data 1007 may also be stored on the mass storage device 1004. Creel mapping data 1007 may be stored in any of one or more databases known in the art. The databases may be centralized or distributed across multiple locations within the network 1015.
- a user may enter commands and information into the computing device 1001 via an input device (not shown).
- input devices comprise, but are not limited to, a keyboard, pointing device (e.g., a computer mouse, remote control), a microphone, a joystick, a scanner, tactile input devices such as gloves, and other body coverings, motion sensor, and the like.
- a human machine interface 1002 that is coupled to the bus 1013, but may be connected by other interface and bus structures, such as a parallel port, game port, an IEEE 1394 Port (also known as a Firewire port), a serial port, network adapter 1008, and/or a universal serial bus (USB).
- a display device 1011 may also be connected to the bus 1013 via an interface, such as a display adapter 1009. It is contemplated that the computing device 1001 may have more than one display adapter 1009 and the computing device 1001 may have more than one display device 1011.
- a display device 1011 may be a monitor, an LCD (Liquid Crystal Display), light emitting diode (LED) display, television, smart lens, smart glass, and/ or a projector.
- other output peripheral devices may comprise components such as speakers (not shown) and a printer (not shown) which may be connected to the computing device 1001 via Input/Output Interface 1010. Any step and/or result of the methods may be output (or caused to be output) in any form to an output device.
- Such output may be any form of visual representation, including, but not limited to, textual, graphical, animation, audio, tactile, and the like.
- the display 1011 and computing device 1001 may be part of one device, or separate devices.
- the computing device 1001 may operate in a networked environment using logical connections to one or more remote computing devices 1014a,b,c.
- a remote computing device 1014a,b,c may be a personal computer, computing station (e.g., workstation), portable computer (e.g., laptop, mobile phone, tablet device), smart device (e.g., smartphone, smart watch, activity tracker, smart apparel, smart accessory), security and/or monitoring device, a server, a router, a network computer, a peer device, edge device or other common network node, and so on.
- Logical connections between the computing device 1001 and a remote computing device 1014a,b,c may be made via a network 1015, such as a local area network (LAN) and/or a general wide area network (WAN). Such network connections may be through a network adapter 1008.
- a network adapter 1008 may be implemented in both wired and wireless environments. Such networking environments are conventional and commonplace in dwellings, offices, enterprise-wide computer networks, intranets, and the Internet.
- creel mapping software 1006 may be stored on or sent across some form of computer readable media. Any of the disclosed methods may be performed by processor-executable instructions embodied on computer readable media.
- a single computing device 1001 can control the various processes, databases, and mechanical components of the creel.
- a computing device 1001 can control each of the service arm, the gantry, and the process mapping.
- a plurality of computing devices can cooperate to control various components of the creel.
- a first computing devices 1001a can control the gantry 100
- a second computing device 1001b can control the service arm 200
- a third computing device 1001c can control the process mapping.
- the third computing device 1001c can interface with the first computing device 1001a and second computing device 1001b to coordinate various operations of the gantry and the service arm.
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Replacing, Conveying, And Pick-Finding For Filamentary Materials (AREA)
- Moulding By Coating Moulds (AREA)
- Warping, Beaming, Or Leasing (AREA)
- Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
- Unwinding Of Filamentary Materials (AREA)
Description
- This invention relates to a creel loading apparatus and a system comprising such a creel loading apparatus.
- In tufting/creeling operations, there is a need for improving safety and decreasing process time, changeover time, labor, and creel variability. The disclosed assemblies, systems, and methods can address one or more of these needs.
DE 83 21 639 U1 discloses a creel loading apparatus according to the preamble of claim 1. - The present invention provides a creel loading apparatus according to claim 1. The creel loading apparatus comprises a frame and a platform that is movable along the frame on a first axis and a second axis that is perpendicular to the first axis. A rotary actuator is configured to rotate at least a portion of the platform about the first axis. A gripper is movably attached to the at least a portion of the platform that is configured to rotate about the first axis. The gripper is configured to releasably engage an inner surface of a yarn package. A linear actuator is configured to move the gripper along a linear actuator axis that is perpendicular to the first axis, wherein the linear actuator comprises a first stage and a second stage, wherein the first stage comprises a servo motor that is configured to move the gripper along the linear actuator axis, and wherein the second stage comprises a pneumatic actuator that is configured to move the gripper along the linear actuator axis.
- At least one camera can be attached to the platform. The at least one camera can be configured to detect a diameter of a measured yarn package corresponding to a remaining quantity of material on the measured yarn package. At least one processor can be is configured to receive an image of the measured yarn package from the at least one camera, and approximate the remaining quantity of material on the measured yarn package based on the image of the measured yarn package.
- The present invention further provides a system according to claim 6 that comprises the creel loading apparatus, a staging area, and a robotic arm comprising a robotic arm gripper at a distal end of the robotic arm. The robotic arm and creel loading apparatus are positioned with respect to the staging area so that the robotic arm can deliver yarn packages to the staging area, and the gripper of the creel loading apparatus can receive the yarn packages from the staging area.
- The system can further comprise a creel, wherein the creel comprises the staging area.
- The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate certain aspects of the instant invention and together with the description, serve to explain, without limitation, the principles of the invention. Like reference characters used therein indicate like parts throughout the several drawings.
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Figure 1 is a schematic top view of any exemplary creel assembly as disclosed herein. -
Figure 2 is a schematic side view of a multi-level creel system with vertically stacked creel assemblies as disclosed herein. -
Figure 3 is a schematic top view of an exemplary feeder assembly for delivering yarn packages to a creel assembly as disclosed herein. -
Figure 4 is a flowchart depicting an exemplary method of using a creel assembly as disclosed herein. -
Figure 5 is a perspective view of a textile manufacturing system comprising a modular creel system and a warper in accordance with embodiments disclosed herein. -
Figure 6 is a perspective view of a portion of a creel of the modular creel system ofFigure 5 . -
Figure 7a is a perspective view of a creel module of the creel ofFigure 6 .Figure 7b is a top view of the creel module ofFigure 7a . -
Figure 8 is a perspective view of an exemplary warper system comprising a single creel module. -
Figure 9 is a perspective view of an exemplary tufting system comprising two creel modules. -
Figure 10 is a perspective view of an exemplary tufting system comprising three creel modules. -
Figure 11 is a perspective view of an exemplary tufting system comprising four creel modules. -
Figure 12 is a perspective view of a gantry for use with the modular creel system ofFigure 5 . -
Figure 13 is a perspective view of a portion of the gantry ofFigure 12 . -
Figure 14 is a perspective view of a gripper of the gantry ofFigure 12 . -
Figure 15 is a perspective view of a staging platform of the gantry ofFigure 12 . -
Figure 16a is a perspective view of the gantry when it is loading the staging platform.Figure 16b is a perspective view of the gantry when the staging platform is loaded and end effectors of the gantry are loaded and in a retracted position.Figure 16c is a perspective view of the gantry when the staging platform is loaded and end effectors of the gantry are loaded and in an extended position. -
Figure 17 is a side view of the gantry ofFigure 12 . -
Figure 18 is a perspective view of a service robot of the textile manufacturing system as inFigure 5 . -
Figure 19 is a perspective view of a gripper assembly of the service robot ofFigure 18 . -
Figure 20 is an underside perspective view of the gripper assembly ofFigure 19 -
Figure 21 is a perspective view of an end of a creel module ofFigure 5 , further illustrating yarn case staging locations. -
Figure 22 is a perspective view of an end of a creel module ofFigure 5 , further illustrating empty yarn case staging locations. -
Figure 23 a perspective view of a staging area of the modular creel system ofFigure 5 . -
Figure 24 is an image of a yarn case taken by a camera of the service robot ofFigure 18 . -
Figure 25 illustrates a method of loading the modular creel system ofFigure 5 . -
Figure 26 is a block diagram of a computing device for use with the textile manufacturing system ofFigure 5 . -
Figure 27 is a block diagram illustrating a plurality of computing devices that cooperate to control the textile manufacturing system ofFigure 5 . - The present invention can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description.
- The following description of the invention is provided as an enabling teaching of the invention in its best, currently known embodiment. Those who work in the art will recognize that many modifications and adaptations are possible within the scope of the present invention as claimed. Thus, the following description is provided as illustrative of embodiments of the present invention and not in limitation thereof.
- As used throughout, the singular forms "a," "an" and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a gripper" can include two or more such grippers unless the context indicates otherwise.
- Ranges can be expressed herein as from "about" one particular value, and/or to "about" another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
- Optionally, in some aspects, when values are approximated by use of the antecedent "about" or "generally" or "substantially," it is contemplated that values within up to 15%, up to 10%, or up to 5% (above or below) of the particularly stated value or characteristic can be included within the scope of those aspects.
- As used herein, the terms "optional" or "optionally" mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.
- Disclosed herein with reference to
Figures 1-4 is acreel assembly 500 having anouter wall 502, a plurality of yarnpackage engagement locations 504, amulti-axis robot 506, and at least one processor. The outer wall can define aninterior space 508, and the plurality of yarnpackage engagement locations 504 can be distributed within the interior space. It is contemplated that the outer wall of eachcreel assembly 500 can be provided in any desired shape, including, without limitation, a circular, square, octagonal, or pentagonal shape. The multi-axis robot can be fixedly secured within the interior space and positioned to selectively engage yarn packages within the interior space. Optionally, themulti-axis robot 506 can be provided on a pedestal. The multi-axis robot can be configured to selectively access the plurality of yarn package engagement locations. The at least one processor can be communicatively coupled to the multi-axis robot and configured to receive an input corresponding to a selected action by the multi-axis robot. Methods of using the creel assembly are also disclosed. - Also described herein are modular creel systems comprising a plurality of the disclosed creel assemblies, with each creel assembly serving as a respective creel module. Optionally, the modular creel systems can comprise an automated feeder assembly configured to selectively deliver yarn packages to the plurality of creel assemblies. Optionally, the plurality of creel assemblies can comprise at least two vertically stacked creel assemblies. Additionally, or alternatively, the plurality of creel assemblies can comprise at least two horizontally adjacent creel assemblies. Methods of using and assembling the modular creel systems are also disclosed.
- In further aspects, it is contemplated that the modular creel system can comprise a plurality of creel assemblies that can be positioned in a first configuration during a first creeling (tufting or warping) operation and that can be positioned in a second configuration during a second creeling (tufting or warping) operation, with the first and second configurations being different from one another. In still further aspects, additional creel assemblies can be coupled to an initial group of creel assemblies in an additive fashion to expand a given creel system.
- Additional details of the disclosed assemblies, systems, and methods are provided below.
- In exemplary aspects, the configuration of the creel will be standard, flexible, and modular to provide creel warping and tufting cells. In these aspects, it is contemplated that each creel assembly can function as a creel module.
- Optionally, in further exemplary aspects, the disclosed creel assemblies can fit within a floor space of 42 feet (12.8016 m) wide by 49 feet (14.9352 m) long with a max ceiling height of 20 feet (6.096 m). In providing a modular creel, the creel's footprint can be expanded or shrunk, depending on the need. Accordingly, creels having smaller footprints can be provided.
- Optionally, in further exemplary aspects, the multi-axis robot of each creel assembly can be a centrally-located servicing robot.
- Optionally, in further exemplary aspects, the feeder assembly can comprise a robotic feeder assembly.
- Optionally, in exemplary aspects, the multi-axis robot of each creel assembly can have a robotic arm mounted to the floor (e.g., using a base) or the ceiling (e.g., using a gantry) of the creel assembly. In these aspects, it is contemplated that the robotic arm can be configured to use 360 degree access to reach all yarn positions within the yarn assembly.
- Optionally, in exemplary aspects, the creel system can be a multi-level system that can be added or subtracted onto to achieve a desired creel configuration for warping or tufting operations. It is contemplated that the number of stacked creel assemblies can be two or three, with most operations being conducted with a two-level stacked configuration.
- Optionally, in exemplary aspects, upper levels of the disclosed creel systems can comprise catwalk linkages to adjacent creel assemblies. In use, it is contemplated that these catwalk linkages can allow operators to access multiple creel assemblies at the same level without having to climb up and down, thereby maximizing human labor efficiency and productivity.
- Optionally, in exemplary aspects, upper levels of the disclosed creel systems can comprise a bolt on
catwalk 520 surrounding the operating area and a mechanism (e.g., a ladder) for accessing the upper level from a lower level within the creel system. - Optionally, within each creel assembly, it is contemplated that a creel section (i.e., a vertical column of yarn package engagement locations) can be no more than 6 or 8 (even numbers) yarn cones high. It is contemplated that the use of a limited, even number of yarn cones in this fashion can allow for use of a dual or quad end effector (coupled to the robot arm) to make the loading/unloading process more efficient. Although creel assemblies as disclosed herein are not limited to cone-style packages, for the purposes of the disclosure it should be understood that the terms yarn cone and yarn package are used interchangeably herein.
- In use, it is contemplated that the plant operator can selectively adjust the yarn package engagement locations and positions of creel assemblies to achieve a designated creel configuration, for example, by engaging a manual mode.
- In one non-limiting example, it is contemplated that each creel level within a creel system can service at least 1,844 cone positions (a two-level can service at least 3,688 cone positions). However, it is contemplated that each creel level can be configured to service more or fewer cone positions depending upon the creel assembly configuration and space constraints.
- Optionally, in exemplary aspects, the bases of the disclosed multi-axis robots are stationary.
- Optionally, in further exemplary aspects, the disclosed creel assemblies and creel systems do not include or make use of vision systems.
- In exemplary aspects, it is contemplated that all yarn cone locations (yarn package engagement locations) are fixed within a given creel assembly.
- In further exemplary aspects, the
creel operator 512 can have zonedaccess 510 from the perimeter of each yarn assembly to permit performance of tying and splicing tasks. It is contemplated that all non-maintenance access to the creel can be provided from outside the wall of the creel assembly. While one zone can have human interaction (an interface mode), other zones (optionally, all other zones within the creel assembly) can be in a running or operational order or mode. Within each creel level, the number of zones configured for human interaction can be selectively adjusted. Optionally, within each creel level, it is contemplated that the number of zones configured for human interaction can range from four to eight. - In exemplary non-limiting aspects, the disclosed robotic components can be manufactured by ABB or Yaskawa (Motoman).
- In exemplary non-limiting aspects, it is contemplated that the disclosed creel assemblies and creel systems can comprise processing units, including programmable logic controllers (PLCs), to permit communication among the various system components. Optionally, such PLCs can be AB L83 PLCs manufactured by Allen Bradley.
- In exemplary non-limiting aspects, it is contemplated that the disclosed creel assemblies and creel systems can comprise one or more drive systems for effecting movement of yarn packages. Optionally, such drive systems can be manufactured by Yaskawa.
- In exemplary non-limiting aspects, it is contemplated that the disclosed creel assemblies and creel systems can comprise at least one human-machine interface (HMI) for receiving inputs from a creel operator. Optionally, such HMIs can be provided as a
Siemens 22" Comfort Panel; however, it is also contemplated that portable HMIs such as tablets and other remote computing devices (e.g., smartphones) can be used. - In further exemplary aspects, each creel assembly can have a
maintenance access door 514 to permit access to the stationary robot within the creel assembly. In these aspects, it is contemplated the maintenance access door can have an emergency stop protocol (e.g., an emergency stop switch that is triggered) if opened during operations. For example, all moving parts can be halted. It is further contemplated that the maintenance access door can be formed as a portion of the outer wall of the creel assembly such that the inner surface of the access door can be used as creel space. - In further exemplary aspects, it is contemplated that all yarn exit points can be oriented upwardly, with the yarn curving over the top of the outer wall of the creel assembly to bridge the distance between the creel assembly and the tufting and/or warping machine(s).
- In still further exemplary aspects, it is contemplated that each creel level can have at least one status light (e.g., at least one Andon light) that is communicatively coupled to a processor and configured to provide an indication of a status of system automation. For example, the status light(s) can vary between on and off, vary between solid and flashing, vary in flashing frequency, and/or change color depending on the status.
- In use, cones of yarn (i.e., yarn packages) can be picked from an inbound pallet location. Optionally, machine vision can be used to effectively find cones of yarn on a pallet and place them on an inbound system such as a conveyor.
- In exemplary aspects, as each yarn cone is picked off the pallet, a plastic cap, as known in the art, can be installed on the yarn cone.
- In further exemplary aspects, cones of yarn fed into the creel can be provided with indicia that can be scanned to verify lots of yarn and consumption amounts/rates. It is contemplated that this can be done within the creel or outside of the creel via auxiliary automation.
- In further exemplary aspects, the robot within each creel assembly can comprise an end effector that loads multiple cones at a time. Optionally, the end effector can be a dual, tri, or quad end effector. It is contemplated that the creel assembly can have a singular end effector to manipulate around the yarn in process.
- In use, after cones are placed into the package creel transport mechanism (as further disclosed herein), the robot can place plastic caps onto the ends of the yarn package.
- In exemplary aspects, a programming interface can be provided to receive one or more inputs corresponding to a proper creel configuration. In these aspects, it is contemplated that locations of the cones and creel population configurations can be stored in memory and associated with particular processes and operations.
- For a multilevel creel system (at least two stacked modular systems), an electro mechanical dumbwaiter can be bolted or otherwise secured onto the exterior of the creel. The dumbwaiter can comprise a platform that selectively moves vertically along the creel. It is contemplated that the dumbwaiter can be configured to deliver a selected number of yarn packages (e.g., four yarn packages) at a time. Optionally, it is further contemplated that the creel system can comprise a light (e.g., an Andon light) that provides a visual indication when the dumbwaiter is in service and safety protocol to prevent human injury. However, it is contemplated that other visual indicators and safety protocols can be used.
- In further exemplary aspects, a separate scanner or camera can be provided with the end effector and configured to produce an alert or signal indicative of a yarn cone position that is empty and/or in need of prompt attention. In use, it is contemplated that the alert or signal can be received by the processing units within the automated yarn system as disclosed herein. It is further contemplated that the alert or signal can be received by a creel operator (optionally, through a remote computing device accessed by the operator).
- In operation, during idle time, the robot of each yarn assembly can be configured to continually scan for empty cone positions. During an "Auto" mode, the robot can be configured to replace an empty yarn cone without prompting from a creel operator. During a "manual" mode, the operator can be responsible to make a decision and to provide at least one input directing the replacement of a cone of yarn or a swap between yarn cone positions.
- After the cones of yarn are depleted, the robot can be configured to remove the cones and place them in a location to be removed from the cell via conveyance or a gravity chute, or placed into a container by a service robot.
- Optionally, in exemplary aspects, the yarn system can comprise collision prevention systems provided on the robotic arms to detect if a human mistake is made and the robot tries to load a position that is already loaded. Additionally, in these aspects, if the robot goes to pick up a cone of yarn and there is not one there, the robot can be configured to scan for a minimum cone diameter in order to evaluate and confirm whether there is no yarn present. In both of these conditions, the robot can be configured to enter a fault condition and provide feedback on the HMI to prompt manual intervention by a creel operator.
- A human interface can be provided as a remote computing device (e.g., tablet, portable electronic pad, smartphone, or the like) or other conventional HMI device. In use, the human interface can allow a creel operator to make manual changes of yarn positions for optimization of the creel and to minimize waste of yarn. Logic within the creel can maintain track of cone locations and alert the creel operator if they assign a populated location mistakenly.
- In use, creel operators can manually tie or splice ends of yarn together. It is contemplated that these creel operators can be provided with zoned access from the perimeter of the wall of each creel assembly. While a creel operator is within a particular zone, the robotic arm can continue to service the other zones of the creel assembly (module) (i.e., except for where the zoned section is interrupted for manual work, operations within the creel assembly will continue).
- In operation, it is contemplated that the HMI interface can display live positions of yarn within the creel. Optionally, in these aspects, the monitoring of live positions of yarn can be done with logic and not sensors. Although not preferred due to complexity and the number of sensors necessary to track yarn locations, it is contemplated that sensors can be used as well.
- In exemplary aspects, each creel assembly can have a display monitor (optionally, a 55" monitor) to show the live view and live status of all creel locations with picture-in-picture (PIP) of one or two cameras within the creel assemblies to permit monitoring of activity inside the operating area. Optionally, it is contemplated that each creel can have remote viewing, monitoring, and diagnostic capability.
- In exemplary non-limiting aspects, each creel location can be configured to accommodate a cone of yarn up to 15" (38.1 cm) in diameter.
- Optionally, each cone can have a 2.75" (6.985 cm) inside diameter and a 3-1/8" (7.9375 cm) outside diameter.
- Optionally, each yarn cone can be 11-7/16" (29.05125 cm) in length.
- Optionally, the automation disclosed herein can be configured to handle up to a 25 lb (11.3398 kg) cone of yarn at each yarn cone position. Optionally, in some aspects, a dual end effector can have a 50 lb (22.6796 kg) capacity. If a tri end effector is used, it is contemplated that the end effector can have a 75 lb (34.0194 kg) capacity. If a quad end effector is used, it is contemplated that the end effector can have a 100 lb (45.3592 kg) capacity.
- In exemplary aspects, it is possible for the creel to have a plurality (e.g., 4-6) of different types of yarns loaded into the creel at the same time. In these aspects, it is contemplated that the programming logic of the creel can allow a creel operator to load the creel in any configuration within the total number of yard positions.
- In further exemplary aspects, each cone of yarn can be verified via scanning an associated barcode (or other indicia) prior to entering the creel.
- In still further exemplary aspects, the HMI can keep track of the yarn ID on the display (screen) for the operator to know what yarn type is running in a particular location within the creel.
- In operation, the HMI can provide the ability to do yarn optimization in either a manual fashion or using automated processor control. Optionally, in one example, the HMI can be configured to permit movement of yarn cones from one position to another position in a manual fashion to provide optimization near the end of a tufting run.
- An exemplary loading process can begin with a lift driver or AGV delivering a pallet of yarn to a fixed inbound/
outbound position 530. The dunnage can be stripped and discarded by manual labor. The HMI can be set to operate in an "Auto" mode and used to load the creel. Amaterial handling robot 532 can locate each package of yarn and load the yarn package into the proper position for transport into the creel. If the robot discovers nonconforming packages, the system can produce an alarm and alert the creel operator to remove the package of yarn. The material handling robot can place plastic caps onto the packages before entry into the creel. Once a pallet has been completely loaded, the material handling robot can generate an alarm and call for an additional pallet of yarn; alternatively, an additional pallet can be automatically indexed into position for engagement with the material handling robot. In exemplary aspects, yarn delivery can be staged on aconventional conveyor 534 or a just-in-time (JIT) delivery conveyor. Once the pallet is empty, the pallet can be transported to an outbound position for takeaway. The loaded yarn can then be transported into the creel using the conveyor assembly. Optionally, it is contemplated that the walls of the creel assemblies can be provided with one or more openings for receiving portions of the conveyor assembly and permitting delivery of yarn packages to a location that is accessible from the robots within the interior spaces of the creel assemblies. Human creel operators can make all yarn connections to ensure that each yarn cone is connected to the tufter. - When the automation components of a creel assembly (creel module) are in an "Auto" mode, the automation can be configured to load a package of yarn (received from the conveyor assembly) onto a selected position within creel assembly in the same general manner in which yarn packages are loaded by the material handling robot. During operation, the robot within each creel assembly, when in "Auto" mode, can be configured to use a scanning end effector to look for empty cones of yard and deposit them into an ejection shoot.
- If the creel assembly is in "Manual" mode, then the HMI and Andon lights can prompt the operator to give instruction to move a cone of yarn from one position to another or to load a new cone automatically. It is contemplated that this process can be employed to optimize yarn usage. In exemplary aspects, it is contemplated that human creel operators can connect or disconnect all yarn connections to ensure that no cones are pulled out of the tufter.
- In further exemplary aspects, human creel operators disconnect all yarn connections to ensure that no cones are pulled out of the tufter. After a yarn cone is disconnected, the HMI can be placed in "Strip" mode to strip the creel. In this mode, yarn is transported out of the creel, and all leftover cones of yarn can be transported by the material handling robot to the outbound position. As the pallets become full, a lift driver or AGV can remove the full pallet and replace the full pallet with an empty pallet for loading additional yarn cones.
- Once the creel is empty, the system can be configured to alert the HMI that the creel is empty and turn on a light (e.g., an Andon light) or other visual indicator to ready itself for loading.
- Referring to
Figures 5 and6 , atextile manufacturing system 2 can comprise acreel 4 and a warper 6 or other yarn processing apparatus such as a tufter or a heat set tunnel. Thecreel 4 can comprise a plurality ofcreel modules 10. Eachcreel module 10 can comprise an outer wall 12 and a plurality of yarnpackage engagement locations 14. The yarnpackage engagement locations 14 can bebullhorns 16 that comprise a generallycylindrical portion 18 and aspreader 20 that biases outwardly against an interior of a yarn package in order to retain the package on the yarn package engagement location. Pull-off guides 22 (e.g., half-cylindrical pull-off guides) can be axially aligned with, and positioned below, thebullhorns 16. - One or more creel modules can cooperate to form a
creel 4 that feeds a yarn processing apparatus. According to various embodiments, a creel can comprise a plurality of modules (e.g., between one and twenty modules). Referring also toFigures 7a and7b , eachcreel module 10 can comprise afirst side 30 and an opposingsecond side 32, wherein thefirst side 30 andsecond side 32 are spaced by apassage 34 through which a gantry travels as further disclosed herein. Each side can comprise a plurality of sections 36 (e.g. between two and twenty sections). Each section can comprise a plurality of horizontal rows (e.g., between six and twenty rows) and a plurality of vertical columns (e.g., four columns) of yarnpackage engagement locations 14. Optionally, each section can be positioned between respective horizontal separators of the frame of the creel as shown inFigures 7a-7b . Each module can comprise one or a plurality oflevels 38. Acatwalk 40 at eachlevel 38 can provide operators with access to the creel. - Referring to
Figure 8 , in a first embodiment, awarper system 2a can comprise asingle creel module 10. Optionally, thesingle creel module 10 can be two levels high, with eight sections per side. Thesingle creel module 10 can hold 640 packages, or 320 ends, that are connected to a warper 6. Referring toFigure 9 , in a second embodiment, atufting system 2b can comprise a pair ofcreel modules 10. The pair ofcreel modules 10 can be two levels high and have ten sections per side. The pair ofcreel modules 10 can, in combination, hold 1844 packages, or 922 ends, that are connected to a tufting machine. It is contemplated that two packages can be connected so that as a first package that is attached to a given needle becomes exhausted, the second (transfer) package can continue to provide yarn to the needle. Referring toFigure 10 , in a third embodiment, atufting system 2c can comprise threemodules 10. The tufting system can be two levels high with five sections per side. The threecreel modules 10 can, in combination, hold 1844 packages, or 922 ends, that are connected to a tufting machine. Referring toFigure 11 , in a fourth embodiment, atufting system 2d can comprise fourmodules 10. The tufting system can be two levels high, with ten sections per side. The tufting system can hold 3688 packages, or 1844 ends, that are connected to a tufting machine. In a fifth embodiment, a yarn creel system can comprise a single module one level high with eight sections per side that can hold 640 packages, or 320 ends, that are connected to a heat set tunnel. In some embodiments, a plurality ofcreel modules 10 can be coupled to form an enlarged creel, for example, to perform a tufting operation. At least one of the plurality of creel modules can be decoupled from the other creel modules of the plurality of creel modules after the tufting operation to form a smaller creel (with fewer creel modules). Due to the modularity of the creel system, further creel module combinations can be provided as desired. - Each
creel module 10 can have a respective creel loading apparatus. Referring toFigures 12 and13 , a creel loading apparatus, organtry 100, in accordance with the present invention, comprises aframe 102. Theframe 102 can comprise ahorizontal track 102a and amast 102b that is movable via a motor (e.g., a servo motor) on thehorizontal track 102a along afirst axis 106. Theframe 102 can includeintegrated conduits 103 for providing power, air, and a vacuum source. Aplatform 104 can comprise afirst portion 104a that moves vertically, via a motor (e.g., a servo motor), along themast 102b. Thus, theplatform 104 is movable along the frame relative to thefirst axis 106 and a second (vertical)axis 108. The platform can further comprise a second portion 104b that is rotatable with respect to thefirst portion 104a about arotary axis 109 that is parallel to thefirst axis 106. Arotary actuator 112 can be configured to rotate the second portion 104b of theplatform 104 about therotary axis 109. Agantry control panel 107 can attach to themast 102b. - A first
linear actuator 112 can be attached to the second portion 104b of theplatform 104. The firstlinear actuator 112 can be extendable along a linear actuator axis 114. Agripper 116 can attach to an end of the firstlinear actuator 112. Optionally, thegripper 116 can be provided as a component of end of arm tooling (EOAT). Thegripper 116 can comprise a plurality ofjaws 118 that extend radially from each other in order to grip an inner surface 122 (Figure 6 ) of ayarn package 120. The plurality ofjaws 118 can optionally have cylindrical surfaces. Thus, thegripper 116 can optionally define a cylindrical surface. - The linear actuator comprises a
first stage 130 and asecond stage 132. Thefirst stage 130 can comprise a sub platform 134 that is movable on a track 136 along the linear actuator axis 114. Aservo motor 138 can drive abelt 140 to move thesub platform 132 along the track 136. Thesecond stage 132 can comprise apneumatic actuator 142 that is attached to the sub-platform 132 so that movement of thefirst stage 130 translates thepneumatic actuator 142 along the linear actuator axis 114. Thepneumatic actuator 142 can comprise a pneumatic cylinder 144 having apiston rod 146 therein. Thegripper 116 can attach to a distal end of thepiston rod 146. - As further disclosed herein, a service robot can stage yarn packages in a staging area within the creel, and the gantry can then transport the yarn packages from the staging area to desired yarn package engagement locations on the creel. In order to be more accessible to the service robot, the staging area can be set closer to a central plane that includes the
first axis 106 and thesecond axis 108. Thus, thefirst stage 130 can position the grippers in a first transverse position, relative to a transverse horizontal axis that is perpendicular to thefirst axis 106, from which the grippers can selectively access, via extension of thesecond stage 132, yarn packages in the staging area. Thefirst stage 130 can then position the grippers in a second transverse position relative to the transverse horizontal axis from which the grippers can selectively position, via extension of thesecond stage 132, yarn packages on yarn package engagement locations on the creel. - Moreover, the dual stage actuator can enable the gantry to be configured for use in various creel module widths (i.e., the horizontal dimension perpendicular to the creel module's longitudinal dimension). For example, the
first stage 130 can be set at a fixed position during normal operation, and thesecond stage 132 can be used for placing the yarn packages. Additionally, the first stage's position can be adjusted to improve positioning of the yarn packages with respect to the yarn package engagement locations when thesecond stage 132 is fully extended. - In some embodiments, a second
linear actuator 150 and a thirdlinear actuator 152 can attach to the second portion 104b of theplatform 104, wherein each of the second linear actuator and the third linear actuator has the same construction and configuration as the firstlinear actuator 112. Each of the secondlinear actuator 150 and the thirdlinear actuator 152 can have agripper 116 attached at a distal end. In this way, thegantry 100 can manipulate threeyarn packages 120 at a time. Each of the firstlinear actuator 112, the secondlinear actuator 150, and the thirdlinear actuator 152 can be independently actuatable. Additionally, the firstlinear actuator 112, the secondlinear actuator 150, and the thirdlinear actuator 152 can be movable in concert (i.e., simultaneously or sequentially). In further embodiments, the gantry can comprise two, four, five, or more linear actuators and respective grippers can independently manipulate a corresponding number of yarn packages. The linear actuators and respective grippers can collectively be referred to asend effectors 158. - Referring to
Figure 17 , a first camera 160 can attach to the second portion 104b of theplatform 104. The first camera 160 can be configured to detect a diameter of ayarn package 120. The first camera 160, and each of the cameras described herein, can optionally be an IFM O3D302. A computing device 1001 (Figure 19 ) in communication with the camera 160 can be configured to approximate a remaining quantity of material on theyarn package 120. For example, the first camera 162 can be at a fixed position from each yarn package on the respective yarn package engagement location. The remaining quantity of yarn can be approximated based on the amount of area that the yarn package encompasses within the camera's field of view. In some embodiments, the measurement error can be within plus or minus five percent. In some embodiments, the first camera can be disposed so that it captures images ofyarn packages 120 on a first side (with respect to a plane that includes thefirst axis 106 and the second axis 108) of the gantry, and a second camera 162 (labeled but not shown) can be disposed opposite the first camera so that it can capture images ofyarn packages 120 on the opposite side of the gantry. - Referring to
Figure 15 , astaging platform 170 can be movable along theframe 102. Thestaging platform 170 can attach to themast 102b so that thestaging platform 170 moves along thefirst axis 106 with theplatform 104. The staging platform can comprise a plurality ofbullhorns 172 that are configured to receiveyarn packages 120 thereon. Thebullhorns 172 can be positioned so that when the second portion 104b of theplatform 104 is rotated so that the linear actuators axes are vertical, the bullhorns are axially aligned with the respective linear actuators' axes 114. Thus, the plurality ofgrippers 116 can hold a first plurality ofpackages 120, and the staging platform can hold a second plurality ofpackages 120. As further disclosed herein, thegrippers 116 can position the first plurality ofpackages 120 on the creel module 10 (Figure 5 ). Therotary actuator 112 can then rotate the second portion 104b of theplatform 104 so that the plurality ofgrippers 116 are oriented to engage the second plurality ofpackages 120 on thestaging platform 170. The plurality ofgrippers 116 can extend and receiverespective packages 120 of the second plurality of packages, retract, and then rotate (optionally, rotating ninety degrees) in order to position the second plurality of packages on thecreel module 10. - Referring to
Figure 23 , thecreel module 10 can comprise astaging area 190 at a first end. A yarncase staging location 196 can receive one ormore yarn cases 198 having a plurality ofyarn packages 120 thereon. The yarncase staging location 196 can comprise guides 197 (Figure 15 ) for locating theyarn cases 198. Thestaging area 190 can comprisebullhorns 192 that are similar tobullhorns 16 and are configured to receive yarn packages 120. The bullhorns can be vertically spaced along a vertical axis so that when theplatform 104 is in ahome position 180, thegrippers 116 can be positioned to simultaneously receive the yarn packages from the staging area'sbullhorns 192. In some embodiments, eachcreel module 10 can comprise a pair of opposingstaging areas 190 that each comprise two rows of three vertically spacedbullhorns 192. - Referring also to
Figure 18 , aservice robot 200 can be disposed with respect to thestaging area 190 and the yarncase staging location 196 so that the service robot can receive yarn packages from the yarn cases in the yarncase staging location 196 and loadyarn packages 120 onto thebullhorns 192 of thestaging area 190. Theservice robot 200 can comprise a base 202 that is anchored to the floor. Anarm 204 can have afirst end 206 that attaches to thebase 202 and anoperational end 208 opposite thefirst end 206. Thearm 204 can have at least four degrees of freedom. In some embodiments, theservice robot 200 can have six axes of movement. Theservice robot 200 can comprise a plurality of actuators that are configured to actuate movement between respective arm components at each arm joint. Agripper assembly 210 can attach to theoperational end 208 of thearm 204. Thegripper assembly 210 can comprise a plurality of grippers 116 (e.g., three grippers) that are spaced so that they can simultaneously load thebullhorns 192 of the staging area (i.e., having the same spacing as that of thegrippers 116 on the gantry). - Referring also to
Figure 19 , according to further aspects, thegripper assembly 210 can comprise a central gripper 116a that is in a fixed position with respect to thegripper assembly 210. Thegripper assembly 210 can further comprise a first gripper 116b on a first side of the central gripper 116a and a second gripper 116c on a second side, opposite the first side, of the central gripper 116a. The first and second grippers 116b, 146c can be coupled (e.g., attached) to respectivelinear actuators 212 that position the respective first or second actuator closer to and away from the central gripper 116a to accommodate variations in spacing of yarn packages. Thelinear actuators 212 can be in communication with a processor of a computing device as disclosed herein that controls their actuation. In some embodiments, thelinear actuators 212 can have about two inches (5.08 cm) of travel. In one exemplary embodiment, yarn packages can be spaced 10.5 inches (26.67 cm) from center to center when on a case, bullhorns in the staging area can be spaced 12.5 inches (31.75 cm) apart from center to center. Thus, thelinear actuators 212 can provide the travel to adapt for the spacing difference. - Referring also to
Figure 20 , the service robot 200 (Figure 18 ) can further comprise acamera 220. Thecamera 220 can be a three-dimensional camera. Thecamera 220 can be in communication with a computing device 1001 (Figure 26 ). Thecomputing device 1001 can receive images of a givenyarn case 198 in the yarncase staging location 196 from thecamera 220 and process the images to determine a quantity ofyarn packages 120 on said case. The camera can be a range camera. That is, the camera (and a coupled processor) can determine a distance between the camera and an object (e.g., a yarn package 120). The camera and coupled processor can be configured to determine presence or absence of yarn packages in a horizontal array. For example, a yarn case can comprise a plurality of stacked horizontal layers. The camera can capture the top layer for determining the presence or absence of yarn packages on the top layer. For example, referring toFigure 24 , the system can detect the missing package 250 (i.e. an empty location without a package present). The camera and coupled processor can further be configured to determine a height of yarn packages, corresponding to a number of stacked layers of yarn packages. - Referring to
Figures 20-22 , thegripper assembly 210 can comprise adunnage removal assembly 230. The dunnage removal assembly can comprise one ormore suction cups 232. Eachsuction cup 232 can be in fluid communication with a vacuum source 234 (e.g., a hose can extend between a vacuum pump and thesuction cup 232. The suction cups 232 can be configured to grip dunnage 186 (Figure 18 ), and the service robot 200 (Figure 18 ) can then move thegripper assembly 210 to lift the dunnage from thecase 198. Theservice robot 200 can then move the dunnage to a dunnage area 188 (assuming thedunnage area 188 has capacity to receive the dunnage; if the dunnage area is full, the system can notify the operator via, for example, a message or an indicator, that the dunnage area must be emptied). Theservice robot 200 can repeat the dunnage removal process for a plurality of layers of dunnage. - In some embodiments, the
yarn case 198 can be received in a designated position (e.g., a yarn case staging location 196). The yarn packages 120 on a givenyarn case 198 can be in fixed positions on the yarn case. In this way, theservice robot 200 can, in knowing the position of theyarn case 198, determine the positons of eachyarn package 120. - The textile manufacturing system 2 (
Figure 5 ) can be controlled by a .net application on a computing device 1001 (Figure 26 ). Operators can interface with the .net application via an input/output interface 1010 (Figure 26 ). In some embodiments, the interface can enable the operator to control operation of the creel system. For example, the operator can input a stock keeping unit (SKU) corresponding to a final flooring (e.g., carpet) product (referred to as a "finished product SKU"), thereby causing thecomputing device 1001 to load the mapping database for the finished product SKU. Further, the interface can provide the operator with information about the process, such as whether or not certain packages need to be loaded onto the creel, in which yarn case staging locations yarn cases comprising such packages need to be positioned so that thetextile manufacturing system 2 can load the yarn cases, or whether certain packages need to be spliced. - Each finished flooring product can have a corresponding SKU. Each finished product SKU can have a corresponding creel map that can be programmed and uploaded into the
computing system 1001. - Referring to
Figure 25 , the computing device 1001 (Figure 26 ) can perform amethod 400 for assigning and monitoring staging of yarn packages. From a starting block 405,method 400 can proceed to stage 410, where thecomputing device 1001 receives a finished flooring product identifier. For example, an operator can input a specific finished flooring product identifier (e.g., a finished product SKU) into thecomputing device 1001. Fromstage 410, themethod 400 can proceed to stage 415, where thecomputing device 1001 receives a creel map. For example, thecomputing device 1001 can receive (e.g., download from a database, as further disclosed herein), based on the input finished product identifier, a creel map comprising a plurality of yarn engagement locations and respective identifiers corresponding to yarn packages to be received at each yarn package engagement location. Thus, the map can store each yarn package engagement location and link each yarn package location to a corresponding yarn package SKU. - The map can be displayed (e.g., on the display of a computing device) as a spreadsheet comprising a first column that lists each yarn engagement location, and a second column that lists the yarn package identifier for the corresponding yarn engagement location. The respective identifiers can be, for example, SKUs of each yarn package. In further embodiments, the map can be displayed as a visualization of the creel. For example, the map can be displayed as a three-dimensional rendering of the creel having different colors, text, and/or graphics corresponding to different yarn package SKUs.
- From
stage 415, themethod 400 can proceed to stage 420, where thecomputing device 1001 can assign yarn case staging locations. That is, the computing device can, using the creel map, assign yarn case staging locations for receiving respective yarn cases. Each yarn case can comprise a pallet having a plurality of yarn packages that each have the same identifier (e.g., SKU). Thus, for a map comprising a first yarn identifier and a second yarn identifier, the computing device can assign a first staging location for receiving a yarn case having yarn with the first identifier and a second staging location for receiving a yarn case having yarn with the second identifier. Fromstage 420, themethod 400 can proceed to stage 425, where thecomputing device 1001 determines the yarn cases (if any) that should be positioned at each yarn case staging locations. For example, the computing device can provide, on a display, a map of each yarn case staging location and a given yarn case identifier designated to be received at each yarn case staging location. Optionally, the map can include at least one yarn case staging location that is empty. - Assigned yarn cases can then be received at each respective yarn case staging location. For example, a forklift operator or automated guided vehicle can position each yarn case at its respective yarn case staging location. From
stage 425,method 400 can proceed to stage 430, where thecomputing device 1001 detects a yarn case at a yarn case staging location. The staging locations can comprise pallet sensors. For example, the pallet sensors can be load sensors that can detect when a sufficient weight is placed in a respective staging location. In further embodiments, a pallet sensors can each be a laser that emits a beam across the yarn case staging location and into a photodetector. When a case is placed in the respective staging location, the yarn case can block the laser from hitting the photodetector, and thecomputing device 1001 can receive a change in signal from the photodetector corresponding to a case being placed in the staging location. - From
stage 430,method 400 can proceed to stage 435, where the computing device receives an identifier of a yarn case positioned at each yarn case staging location. According to some aspects, using a handheld scanner in communication with acomputing device 1001, the operator can scan an identifier (e.g., a barcode, QR code, RFID (radio frequency identification) tag, etc.) that corresponds to a yarn case staging location. Optionally, the handheld scanning function can be performed using thecomputing device 1001, for example, using a camera and an optical scanning application of the computing device. The operator can then scan an identifier (e.g., a barcode, QR code, RFID tag, etc.) on the yarn case. The scannable identifier that corresponds to the yarn case staging location can optionally be located at a position at or near the yarn case staging location so that an operator at the yarn case staging location can scan both the yarn case staging location identifier and the identifier on the yarn case that is positioned on the yarn case staging location from the same standing position. Fromstage 435,method 400 can proceed to stage 440, where the yarn case identifier is compared to the yarn case staging location. The computing device can determine whether the yarn case is a correct match for the given staging location. Fromstage 440,method 400 can proceed to stage 445, where feedback is provided to the operator if the received yarn case identifier does not match the assigned yarn case identifier. If the yarn case identifier is incorrect, the system can display an error and prevent theservice arm 200 from staging the yarn packages until the correct yarn case is positioned in the staging location. - In further embodiments, instead of, or in addition to, using pallet sensors at
stage 430, the system can maintain knowledge of the occupied status (occupied or unoccupied) of each staging location based on scanning yarn cases onto and off of the yarn case staging location. For example, when an operator scans a staging location and then a yarn case, the computing device 1001 (Figure 26 ) can store in system memory 1012 (Figure 26 ) that the staging location is occupied. Similarly, as a yarn case (or empty pallet from the yarn case) is removed, the operator can scan the staging location, thereby causing the computing device to store in thesystem memory 1012 that the staging location is unoccupied. In still further embodiments, RFID or other automated scanning methods can be used to determine when a yarn case is in a staging location. For example, an RFID scanner can be positioned with respect to a staging location so that when a yarn case having a properly-situated RFID tag is placed in the staging location, the RFID scanner can detect the presence of the yarn case. - Once the yarn cases have been received at each yarn case staging location, the
service robot 200 can provide the yarn packages to thegantry 100. The gantry can then deliver the yarn to the respective yarn package engagement locations based on the creel map. - The system memory 1012 (
Figure 26 ) of the computing device 1001 (Figure 26 ) can include a database for monitoring occupancy of yarn packages at each yarn package engagement location. For example, when the gantry places a yarn package on a yarn package engagement location, the computing device can store in the database that the yarn package engagement location is occupied. Thecomputing device 1001 can then check the database before providing instructions to the gantry to place another yarn package. If thecomputing device 1001 receives instructions to place the yarn package on an occupied yarn package location, thecomputing device 1001 can provide an error message or otherwise notify an operator that the yarn package location is already occupied. For example, the error message can include text on a display of a computing device, an audible alarm, and/or a status light on a control panel. - The gantry can purge yarn packages by removing the yarn packages from their respective yarn package engagement locations. In some aspects, the gantry and the service arm can further deliver the purged yarn packages to a bin, or to the yarn staging area from which the service arm receives the purged yarn packages and then places the purged yarn packages in the bin. In further aspects, the service arm can stack the purged yarn packages into a position based on the package design. For example, a pallet can comprise cylindrical or conical studs that are receivable within an inner volume defined by the package's inner surface 122 (
Figure 6 ). Thus, the studs can space the purged yarn packages. When a pallet has a full layer of packages, another pallet can be stacked on top of the full package layer until the case is full, at which point the full case can be removed and replaced with an empty pallet. - The
computing device 1001 can allow for various levels of access. For example, the levels can comprise an operator level, a maintenance level, an engineering level, and an administrator level. Each level can be permitted or restricted access based on certain rules. For example, in some embodiments, operators can be provided access to load creel maps but not edit creel maps, whereas engineers can be permitted to edit creel maps and override certain parameters. - A program, when executed by a processor of the computing device, can enable an operator to select certain operational modes of the creel system. For example, the modes can include a strip creel mode, a load creel mode, a run mode, and a manual creeling mode. In the strip creel mode, the program can prompt the operator to verify that the ends of the yarns have been cut and prevent further operation until the operator verifies as such through the user interface as further disclosed herein. The program can then prompt the operator to verify that RTI bins (e.g., refuse/package recycle bins) are empty and in proper positions. If they are not, the program can prevent further operation until the operator verifies that the RTI bins are both empty (or have available capacity) and in proper positions and provides input indicative of properly positioned bins with available capacity. The processor can then direct the gantry to proceed to strip (i.e., remove yarn packages from) some or all of the creel. Optionally, the operator can select
individual creel modules 10, portions of creel modules, or individual yarn package engagement locations for stripping. - In the load creel mode, the operator can enter or scan a finished product SKU. The program can load the creel map based on the entered finished product SKU and assign yarn case staging locations to receive select yarn cases based on the map. The operator can then scan a yarn case or otherwise input an identifier of the yarn case. The program can verify that the yarn case corresponds to an assigned yarn case from the map. If the yarn case does not match an assigned yarn case, the program can provide such feedback to the operator (through the user interface such as a text or graphical display). If the yarn case matches the assigned yarn case, the program can then allow the operator to scan a yarn case staging location. The program can then determine whether or not the yarn case staging location matches the yarn case. If the yarn case does not match, the program can provide such feedback (e.g., via an error message) and prevent the program from advancing further until the yarn case matches the assigned yarn case staging location. If the yarn case matches the assigned yarn case staging location, the program can prompt the operator to load the yarn case onto the yarn case staging location. Optionally, the program can sense the receipt of the yarn case onto the yarn case staging location. The program can repeat until each yarn case staging location has received its assigned yarn case.
- The operator can then splice/tie ends of the yarn to prepare the creel for operation. Once the ends are tied, the operator can select run mode (through entry of written/typed or oral command through the user interface). The program can prompt the operator to verify that all of the yarn ends are tied. The program can prevent run mode from executing until the operator verifies that the yarn ends were tied
- In the manual creeling mode, the operator can select to move a package from a staging area to a module position. The operator can enter or scan a finished product SKU. For example, the operator can select the finished product SKU from a drop-down menu, type the SKU into a text input box, or scan a barcode from a book of barcodes corresponding to respective final flooring products. If a required yarn package is present either already on the creel or in a yarn case in a yarn case staging location, the system can position the yarn in the desired yarn package engagement location. If a required yarn package is not present either already on the creel or in a yarn case in a yarn package engagement location, the program can enable the operator to scan at least one yarn package. If the yarn package matches the finished product SKU, the program can advance to allow the operator to scan a location (e.g., an operator can use a barcode scanner to scan a barcode positioned at a respective yarn package receiving location). If the scanned location matches or is otherwise associated with the yarn package, the program can advance to allow the operator to load the yarn.
- Additionally, in the manual creeling mode, the program can enable the operator to move a yarn package from a yarn package engagement location to a package staging location. The program can prompt the operator to verify that the yarn ends are cut. Once affirmed, the program can verify locations of RTI bin(s). For example, empty RTI bins can be placed in yarn case staging locations. To verify placement of the empty RTI bins, an operator can scan the identifier (e.g., barcode) of each yarn case staging location and an identifier (e.g., barcode) on the respective RTI bin, thereby inputting into the computing device the location of each empty RTI bin for receiving yarn packages from the creel. If the RTI bin locations are not verified, the program can prompt the operator to load the RTI bins. Otherwise, the gantry can move the yarn package from the yarn package engagement location to the package staging location.
- Further, in the manual creeling mode, the program can enable the operator to move a yarn package from one yarn package engagement location to another. The processor, when executing the program, can prompt the operator to verify that the yarn ends are cut. Once affirmed, the processor, when executing the program, can cause the gantry to move the yarn package from a first yarn package engagement location to a second yarn package engagement location.
- The above-disclosed system can be used according to the following process. An operator can input the SKU of a finished product. For example, the operator can select the finished product SKU from a drop-down menu, type the SKU into a text input box, or scan a barcode from a book of barcodes corresponding to respective final flooring products. In doing so, the system can load the creel map associated with the loaded SKU of the finished product. Yarn cases can then be staged at yarn case staging locations based on the loaded creel map. An operator can gain access into a fenced off pallet staging area via a hard and/or a soft (e.g., input key code) key. The
service robot 200 can be moved to a home position. The home position can be a position in which the service robot is spaced from the travel of the gantry to avoid collision and spaced from the yarn case staging locations to allow placement of yarn cases thereon. The operator can scan the yarn case's SKU and then the corresponding yarn case staging location. The system can prompt the operator to load yarn package caps or verify that yarn package caps are already present on the yarn packages. The operator can verify that the yarn case is properly arranged with respect to the yarn case locators. The system can prevent the service robot from moving until the pallet sensor(s) is/are detecting yarn cases thereon. The service robot, in conjunction with the gantry, can then begin loading the respective creel module and continue until the creel is full (with each engagement location being filled in accordance with the creel map). If the yarn case becomes exhausted (as detected, for example, by the service robot's camera) the system can pause to allow the operator to scan in and load another yarn case at the yarn case staging location, as described herein. When the staging area becomes full, the service robot can go into an idle mode (e.g., motionless in the home position) until the gantry opens space in the staging area. When a layer of yarn packages is removed from the yarn case, the service robot can remove the dunnage and place the dunnage in the empty dunnage area, exposing the next layer of yarn packages for engagement with the grippers of the service robot. - The gantry can begin at a staging wait position (at a position spaced from the staging area). The gantry can wait until the service robot positions a sufficient number of yarn packages in the
staging area 190. The gantry and service robot can maintain knowledge of each other's position in order to avoid collision. For example, the gantry can stay at the staging wait position until the service robot is halted in the home position. The gantry can then load thestaging platform 170 and then load each of itsend effectors 158. The gantry can fill the yarn package engagement locations according to the creel map. - When each of the yarn package engagement locations is full (in accordance with the creel map), the gantry can enter a check mode. In check mode, the gantry can use its cameras to measure the remaining quantity of yarn on each package. When the gantry detects a yarn package that is empty or below a threshold (e.g., a minimum operative diameter based on the amount of remaining yarn), the gantry can remove the exhausted package spool from the gantry and place it in a discard bin. The computing device can determine if a replacement yarn package of the same SKU is available at the creel module's staging area. If one is available, the service robot can place the yarn package in the staging area, and the gantry can place the yarn package in the yarn package engagement location from which the exhausted roll was removed. The system can then notify an operator to splice the yarn. If the yarn package (with the proper SKU) is not available in the
staging area 190, the system can cause the service robot to place the yarn package in the yarn case staging location. - To strip the creel, the ends can first be cut (using conventional methods). At least one container must be in place and have capacity to receive yarn packages (or, preferably, be empty). If no bin is in position and with capacity to receive yarn packages, the system can prompt the operator to place or change the container. The gantry can remove yarn packages beginning from the far end (opposite the service robot) first. The gantry can fill the staging platform 170 (e.g., with three packages) and fill its end effectors. The gantry can then place the packages from its end effectors and staging platform in the
staging area 190. Theservice robot 200 can pick up the yarn packages from the staging area and place them into the container. - Using the creel systems as disclosed herein, the creel can be loaded more quickly than conventional system and methods. For example, in some embodiments, a creel module can be loaded in less than two hours and eight minutes. Because each creel module can be loaded simultaneously, a creel comprising a plurality of modules can likewise be loaded in less than two hours and eight minutes.
-
Figure 26 shows asystem 1000 including acomputing device 1001 for use with the creel system as disclosed herein. - The
computing device 1001 may comprise one ormore processors 1003, asystem memory 1012, and abus 1013 that couples various components of thecomputing device 1001 including the one ormore processors 1003 to thesystem memory 1012. In the case ofmultiple processors 1003, thecomputing device 1001 may utilize parallel computing. In exemplary aspects, thecomputing device 1001 can comprise a tablet, a smart phone, a personal computer, a laptop computer, or other suitable device (e.g., handheld computing device). - The
bus 1013 may comprise one or more of several possible types of bus structures, such as a memory bus, memory controller, a peripheral bus, an accelerated graphics port, and a processor or local bus using any of a variety of bus architectures. - The
computing device 1001 may operate on and/or comprise a variety of computer readable media (e.g., non-transitory). Computer readable media may be any available media that is accessible by thecomputing device 1001 and comprises, non-transitory, volatile and/or non-volatile media, removable and non-removable media. Thesystem memory 1012 has computer readable media in the form of volatile memory, such as random access memory (RAM), and/or non-volatile memory, such as read only memory (ROM). Thesystem memory 1012 may store data such ascreel mapping data 1007 and/or program modules such asoperating system 1005 andcreel mapping software 1006 that are accessible to and/or are operated on by the one ormore processors 1003. - The
computing device 1001 may also comprise other removable/non-removable, volatile/non-volatile computer storage media. Themass storage device 1004 may provide non-volatile storage of computer code, computer readable instructions, data structures, program modules, and other data for thecomputing device 1001. Themass storage device 1004 may be a hard disk, a removable magnetic disk, a removable optical disk, magnetic cassettes or other magnetic storage devices, flash memory cards, CD-ROM, digital versatile disks (DVD) or other optical storage, random access memories (RAM), read only memories (ROM), electrically erasable programmable read-only memory (EEPROM), and the like. - Any number of program modules may be stored on the
mass storage device 1004. Anoperating system 1005 andcreel mapping software 1006 may be stored on themass storage device 1004. One or more of theoperating system 1005 and creel mapping software 1006 (or some combination thereof) may comprise program modules and thecreel mapping software 1006.Creel mapping data 1007 may also be stored on themass storage device 1004.Creel mapping data 1007 may be stored in any of one or more databases known in the art. The databases may be centralized or distributed across multiple locations within thenetwork 1015. - A user (e.g., the creel operator) may enter commands and information into the
computing device 1001 via an input device (not shown). Such input devices comprise, but are not limited to, a keyboard, pointing device (e.g., a computer mouse, remote control), a microphone, a joystick, a scanner, tactile input devices such as gloves, and other body coverings, motion sensor, and the like. These and other input devices may be connected to the one ormore processors 1003 via ahuman machine interface 1002 that is coupled to thebus 1013, but may be connected by other interface and bus structures, such as a parallel port, game port, an IEEE 1394 Port (also known as a Firewire port), a serial port,network adapter 1008, and/or a universal serial bus (USB). - A
display device 1011 may also be connected to thebus 1013 via an interface, such as adisplay adapter 1009. It is contemplated that thecomputing device 1001 may have more than onedisplay adapter 1009 and thecomputing device 1001 may have more than onedisplay device 1011. Adisplay device 1011 may be a monitor, an LCD (Liquid Crystal Display), light emitting diode (LED) display, television, smart lens, smart glass, and/ or a projector. In addition to thedisplay device 1011, other output peripheral devices may comprise components such as speakers (not shown) and a printer (not shown) which may be connected to thecomputing device 1001 via Input/Output Interface 1010. Any step and/or result of the methods may be output (or caused to be output) in any form to an output device. Such output may be any form of visual representation, including, but not limited to, textual, graphical, animation, audio, tactile, and the like. Thedisplay 1011 andcomputing device 1001 may be part of one device, or separate devices. - The
computing device 1001 may operate in a networked environment using logical connections to one or moreremote computing devices 1014a,b,c. Aremote computing device 1014a,b,c may be a personal computer, computing station (e.g., workstation), portable computer (e.g., laptop, mobile phone, tablet device), smart device (e.g., smartphone, smart watch, activity tracker, smart apparel, smart accessory), security and/or monitoring device, a server, a router, a network computer, a peer device, edge device or other common network node, and so on. Logical connections between thecomputing device 1001 and aremote computing device 1014a,b,c may be made via anetwork 1015, such as a local area network (LAN) and/or a general wide area network (WAN). Such network connections may be through anetwork adapter 1008. Anetwork adapter 1008 may be implemented in both wired and wireless environments. Such networking environments are conventional and commonplace in dwellings, offices, enterprise-wide computer networks, intranets, and the Internet. - Application programs and other executable program components such as the
operating system 1005 are shown herein as discrete blocks, although it is recognized that such programs and components may reside at various times in different storage components of thecomputing device 1001, and are executed by the one ormore processors 1003 of thecomputing device 1001. An implementation ofcreel mapping software 1006 may be stored on or sent across some form of computer readable media. Any of the disclosed methods may be performed by processor-executable instructions embodied on computer readable media. - In some embodiments, a
single computing device 1001 can control the various processes, databases, and mechanical components of the creel. For example, in some embodiments, acomputing device 1001 can control each of the service arm, the gantry, and the process mapping. In other embodiments, with reference toFigure 27 , a plurality of computing devices can cooperate to control various components of the creel. For example, afirst computing devices 1001a can control thegantry 100, asecond computing device 1001b can control theservice arm 200, and a third computing device 1001c can control the process mapping. Further, the third computing device 1001c can interface with thefirst computing device 1001a andsecond computing device 1001b to coordinate various operations of the gantry and the service arm.
Claims (8)
- A creel loading apparatus (100)comprising:a frame (102);a platform (104) that is movable along the frame (102) on a first axis (106) and a second axis (108) that is perpendicular to the first axis (106);a rotary actuator (112) that is configured to rotate at least a portion (104b) of the platform (104) about the first axis (106);a gripper (116) that is movably attached to the at least a portion of the platform (104) that is configured to rotate about the first axis (106), wherein the gripper (116) is configured to releasably engage an inner surface (122) of a yarn package (120); anda linear actuator (112) that is configured to move the gripper (116) along a linear actuator axis (114) that is perpendicular to the first axis (106), characterized in thatthe linear actuator (112) comprises a first stage (130) and a second stage (132),wherein the first stage (130) comprises a servo motor (138) that is configured to move the gripper (116) along the linear actuator axis (114), and wherein the second stage (132) comprises a pneumatic actuator (142) that is configured to move the gripper (116) along the linear actuator axis (114).
- The creel loading apparatus (100) of claim 1, further comprising a sub-platform (132), wherein the servo motor (138) is configured to move the sub-platform (132) along a track (136), and wherein the pneumatic cylinder is attached to the sub-platform so that the pneumatic cylinder (144) is in a fixed position along the linear axis (114) with respect to the sub-platform (132).
- The creel loading apparatus (100) of claim 1, further comprising a second gripper (116) and a second linear actuator (150), wherein the second gripper (116) is movably attached to the platform (104) and configured to releasably engage an inner surface (122) of a yarn package (120), and wherein the second linear actuator (150) is configured to move the second gripper (116) along the linear axis (114).
- The creel loading apparatus (100) of claim 3, further comprising a third gripper (116) and a third linear actuator (152), wherein the third gripper (116) is movably attached to the platform (104) and configured to releasably engage an inner surface (122) of a yarn package (120), and wherein the third linear actuator (152) is configured to move the third gripper (116) along the linear axis (114).
- The creel loading apparatus (100) of claim 1, further comprising a camera (160) that is attached to the platform (104), wherein the camera (160) is configured to detect a diameter of a measured yarn package (120) corresponding to a remaining quantity of material on the measured yarn package (120).
- A system comprising:the creel loading apparatus (100) of any one of claims 1-5;a staging area (190); anda robotic arm comprising a robotic arm gripper at a distal end of the robotic arm,wherein the robotic arm and creel loading apparatus (100) are positioned with respect to the staging area (190) so that the robotic arm can deliver yarn packages (120) to the staging area (190), and the gripper (116) of the creel loading apparatus (100) can receive the yarn packages (120) from the staging area (190).
- The system of claim 6, wherein the creel loading apparatus (100) of any of claims 1-4 comprises:at least one camera (160) that is attached to the platform (104), wherein the at least one camera (160) is configured to detect a diameter of a measured yarn package (120) corresponding to a remaining quantity of material on the measured yarn package (120); andwherein the system further comprises:
at least one processor that is configured to:receive an image of the measured yarn package (120) from the at least one camera (160), andapproximate the remaining quantity of material on the measured yarn package (120) based on the image of the measured yarn package (120). - The system of claim 7, wherein the at least one camera (160) comprises a first camera (160) that is disposed on a first side of the platform (104) and a second camera (162) that is disposed on a second side of the platform (104) opposite the first side of the platform (104).
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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EP23218707.0A EP4345040A3 (en) | 2018-07-30 | 2019-07-30 | Creel loading apparatus and system |
Applications Claiming Priority (2)
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US201862711886P | 2018-07-30 | 2018-07-30 | |
PCT/US2019/044160 WO2020028377A1 (en) | 2018-07-30 | 2019-07-30 | Automated creel assemblies and systems and methods of making and using same |
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EP23218707.0A Division EP4345040A3 (en) | 2018-07-30 | 2019-07-30 | Creel loading apparatus and system |
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EP3830012A1 EP3830012A1 (en) | 2021-06-09 |
EP3830012A4 EP3830012A4 (en) | 2022-11-23 |
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EP23218707.0A Pending EP4345040A3 (en) | 2018-07-30 | 2019-07-30 | Creel loading apparatus and system |
EP19844266.7A Active EP3830012B1 (en) | 2018-07-30 | 2019-07-30 | Creel loading apparatus and system |
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EP23218707.0A Pending EP4345040A3 (en) | 2018-07-30 | 2019-07-30 | Creel loading apparatus and system |
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EP (2) | EP4345040A3 (en) |
CN (1) | CN112566859B (en) |
CA (1) | CA3107082A1 (en) |
WO (1) | WO2020028377A1 (en) |
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CN113307100B (en) * | 2021-07-07 | 2023-04-07 | 四川玄武岩纤维新材料研究院(创新中心) | Unmanned intelligent yarn changing system and automatic yarn changing method |
CN113911846B (en) * | 2021-11-11 | 2023-05-09 | 浙江精功机器人智能装备有限公司 | Intelligent textile production system based on AGV trolley |
WO2023183878A2 (en) * | 2022-03-24 | 2023-09-28 | Belmont Textile Machinery Company | Powered creel systems, receiver apparatuses and related methods for yarn packages |
JP2023157296A (en) * | 2022-04-14 | 2023-10-26 | Tmtマシナリー株式会社 | Yarn feeding package replacement method to creel stand, yarn feeding package supply system, and yarn feeding package supply device |
CN116993741B (en) * | 2023-09-28 | 2023-12-22 | 福建旭源纺织有限公司 | Roving uniformity monitoring system and roving uniformity detection device |
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WO2020028377A1 (en) | 2020-02-06 |
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CN112566859A (en) | 2021-03-26 |
US20200031608A1 (en) | 2020-01-30 |
EP3830012A4 (en) | 2022-11-23 |
EP4345040A2 (en) | 2024-04-03 |
EP3830012A1 (en) | 2021-06-09 |
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